【作者】 付文智；

【导师】 李明哲；

【作者基本信息】 吉林大学 ， 材料加工工程， 2004， 博士

【摘要】 多点成形设备（Ｍｕｌｔｉ－ｐｏｉｎｔ　ｆｏｒｍｉｎｇ　ｐｒｅｓｓ，简称 ＭＰＦＰ）是利用了多点成形技术研制成功的先进的板类零件成形设备，其工作原理是将传统的整体模具离散成一系列规则排列、高度可调的调形单元（或称冲头），由这些调形单元组成的“柔性多点模具”代替传统的冲压成形。与整体模具成形方法相比，多点成形设备实现了一机多用的设想，既节省了模具设计与制造所需的大量时间和费用，又可大大降低产品的成本，加速产品的更新换代。在多点成形设备中，调形单元是其核心部分，它的工作性能、可靠性及自动化程度高低直接影响设备的功能强弱，对多点成形设备的实用化、智能化、集成化起着非常重要的作用。探讨多点成形设备的关键部件—调形单元的改进与创新具有重要的实际意义。　本文旨在为多点成形设备开发和研究提供高效、高精度、实用的调形单元。该项研究涉及到机械学、电磁学、液压流体力学、液压控制元件、计算流体力学、有限元理论、金属塑性成形、材料力学、计算机模拟等多项跨学科知识。本文首次对多点成形设备用的调形单元进行了系统研究，探讨了机械式调形单元、比例式液压调形单元及步进式液压调形单元等多种调形单元结构的可行性及关键元件的数值模拟。研究了多点成形设备常用的三种调形方式（串行调形、混合调形及并行调形）及其调形过程、调形单元在成形过程中的受力状态及柔性压边装置的压边力的调整等，开发出了步进式液压调形单元、低噪声恒力电磁离合器、压边装置及电磁换向阀。　本文的主要研究内容与结论如下：　１．　对多点成形设备的总体设计以及调形单元的结构、关键控制元件进行了研究，取得了多项有实用价值的研究成果，在国际上首次实现了多点成形设备的商品化与系列化，研制出 １００ｋＮ，２００ｋＮ，６３０ｋＮ，２０００ｋＮ，３１５０ｋＮ 多点成形设备；其应用领域也不断扩展，实现了在流线型车头覆盖件、建筑装饰件、医用人脑颅骨修复体、潜艇曲面板等的多点成形。本文采用了有限元理论分析了多点成形设备中的关键零部件，为优化设计多点成形设备调形用关键零部件奠定了基础。　２．　对调形单元关键零部件进行了研究，探讨了多点成形设备用调形单元在成形过程中的受力状态。分析多点成形设备用调形单元的类型，从调形方式、控制方式、驱动方式等对不同的调形单元进行了探讨；开发出新型的、紧凑型调形单元，减小了调形单 I<WP=186>吉林大学博士研究生学位论文元在活动横梁和工作台天窗空间尺寸。这些调形单元在多点成形设备成形过程中直接与成形的板材接触，只要调形误差控制在许可的范围内，就可以用于板材成形。　 ３．　开发出适合于多点成形的高柔性压边装置。起皱是薄板多点成形时最典型的成形缺陷；防止工件起皱是薄板曲面件多点成形中的关键技术问题。本文对多点成形工艺进行全面、系统的研究，分析了薄板多点成形时的主要问题及相应的解决措施。针对多点成形柔性可变的特点，开发出一种适用于多点成形设备的高柔性压边装置，为解决薄板多点成形时的起皱缺陷问题，起到了关键作用。经过几年的使用和改进，基本解决了大部分薄板工件多点成形时的起皱问题。　 ４．　开发出低噪声的恒力电磁离合器。在多点成形设备的机械手式调形单元中使用了电磁铁离合器，但电磁铁离合器运动部分的撞击比较大，噪音也比较大。通过对电磁铁离合器工作过程的研究，发现运动部分移动开始时运动比较平稳，但移动到与电磁铁离合器磁轭接触的瞬间电磁铁吸合力特别大。为了改进这种工作状态，提出了电磁铁调节气隙设计法；用该设计法设计了几种调节气隙形状，并对这些改进的设计方案进行了有限元数值模拟，得到了电磁吸力与运动部分位移量的关系，并对几种方案进行比较，得到了与复位弹簧相匹配的电磁铁结构。　 ５．对滑阀式换向阀进行了数值模拟研究。步进式液压调形单元、比例式液压调形单元及被动式液压调形基本体及压边装置都用到了滑阀式换向阀。本文建立了滑阀内三维流场的有限元数学模型，得到了三维流场的液体速度、液体压力的分布规律，利用这些参数计算了液压系统中流量和液体压力，分析了换向阀的稳态液动力在阀高压入口和节流口的分布规律，探讨了阀芯的不同底圆角对滑阀稳态液动力的影响，为进一步开发步进式调形单元、比例式调形单元及被动式基本体（压边装置）提供了理论基础。 ６．对滑阀式换向阀封油间隙与侧向力关系进行了研究。圆柱式配合间隙是设计滑阀类换向阀要考虑的关键问题，本文分阀体孔和阀芯为理想圆柱体、正锥度阀芯、负锥度阀芯等三种状态，在有无偏心时研究了液体压力和液体速度在缝隙内的分布规律。对不同的液体压力、不同的间隙、不同阀芯锥度进行了详细研究，得到了一些有价值的结论。　 当滑阀式的阀体孔和阀芯都是理想圆柱形时，无论配合间隙大小还是阀芯相对阀体孔偏心与否，对阀芯的侧向力均无大的影响，因此这种状况时侧向力与配合间隙和偏心放置几乎无关；当锥度一定，配合间隙改?更多还原

【Abstract】 Multi-point forming press(MPFP for short ) is an advanced forming equipment which isstudied and manufactured with Multi-point forming technology for sheet metal part．Itsoperating principle is that the conventional solid die is made into aserial discrete adjustingelements in which is arranged regularly and whose height can be adjusted. Flexible multi-pointdie composed of these adjusting elements replace conventional solid die. Comparing withconventional solid die, MPFP realizes the imagination that a machine can be used for manyusages; saves a lot of time and expenditure that is required to design and manufacture solid die;decreases the cost of this product and renews quickly. Adjusting elements is core section in theMPFP, it’s working performance, reliability and automatization affect directly the performanceof MPFP and play a important role in MPFP’s practicability, intelligentization and integration.therefore improvement and innovation on MPFP’s key part-adjusting elements have importantpractical sense. This thesis aims at offering every kind of efficient, high accuracy and practical adjustingelements for exploitation and study of MPFP. The project’s research involves many advancedtechnological field, such as the mechanism, the electromagnetism, the hydraulic fluidmechanics, the hydraulically control element, computational fluid mechanics, finite elementtheories, the plastic forming for sheet metal, the material mechanics, numerical simulation etc.three adjusting types (serial adjusting type. blend adjusting type. parallel adjusting type) usedin MPFP and adjusting process of elements were Studied. Secondly, briefly narrating class andstructure characteristic of special adjusting elements of MPFP. The adjusting elements used inMPFP are studied firstly in this thesis; the feasibility and numerical simulation on key elementof many kinds of adjusting element were discussed, such as mechanical adjusting element,proportional hydraulic adjusting element servo-valve adjusting element etc; the force state ofadjusting element in forming process ,forming part quality affected by precision of adjustingelement; adjustability of the blank holder’s force of flexible blank holder ,which were studiedin this thesis. some applicable fruits have been received. Step-adjusting element,electromagnetic clutch with low noise and quasi-constant force, blank holder andelectromagnetic exchange direction valve are empoldered ulteriorly.IV<WP=189>摘　　　　要　 The main research in the thesis is as follows: 1. The MPFP’s structure design. The structure and driving and controlling manner ofadjusting element and its key parts were studied, and many practical fruits have been received,commercialization and serial of MPFP come true internationally. 100kN, 200kN, 630kN,2000kN and 3150kN MPFP were developed and manufactured. MPFP’s applicable field iscontinually expanded, multi-point forming in cover part of streamline high speed train,architecture ornament, cranial titanium prosthesis in hospital, surface sheet of submarine and soforth come true. 2. Studying key component of adjusting element. Type of adjusting element used in MPFPis analyzed, different adjusting element discussed from adjusting manner controlling mannerand driving manner and new type and compact adjusting element are empoldered, so the size isreduced adjusting elements’taken in active transom and worktable. Adjusting element contactsdirectly with sheet metal during forming process of MPFP, position error of adjusting elementis controlled in allowance quantity, adjusting element is used in MPFP 3. Exploitation of blank holder. Wrinkling is representative defect for sheet metal inmulti-point forming.; preventing wrinkling is the key issue in multi-point forming. General andsystemic research of multi-point forming was carried, Primary issue and resolving method forsheet metal were analyzed. In term of the flexible characteristic of multi-point forming, theblank ho更多还原