高强度合金钢管材液压成形试验机的设计与开发

【作者】 刘东升；

【导师】 樊黎霞；

【作者基本信息】 南京理工大学 ， 机械制造及其自动化， 2011， 硕士

【摘要】 管材液力塑性成形技术有效地将结构轻量化和加工柔性化结合在一起,与传统的挤压、冲压及其它的塑性成形技术相比,属于特种塑性加工中新颖的近净成形技术。因此,许多发达国家都对该技术做了大量的研究工作,并逐渐将研究成果由汽车领域向航空航天、军事、生活用品等其他领域推广应用。我国对该技术的研究相对滞后,在成形设备、过程参数控制及模具设计等方面仍相当匮乏,尤其是对高强度合金管材成形研究更少,积极开展高强度合金管材液压成形试验机开发,并最终建立起一套高强度合金钢管形零件液压成形过程计算机仿真的标定验证系统是一项必要且重要的工作。本文先从高强度合金试验管材液力成形性能及成形件的最大几何参数入手,针对两端固定无轴向进给之自由鼓胀成形模型推导出数学解析式,计算成形过程最高工艺参数,最后确定了液压成形试验机的主要技术参数。本液压成形试验机采用四缸合模、四立柱缸浮动及辅助锁模结构,同比增大了合模压力,结构紧凑,提高了有效空间。采用三缸进给及平衡相互转换结构,扩大了成形范围。另外,本机实现了模块化及轻量化结构,减轻机身重量,并能实现多台机组合工作成形大型工件。在液压系统中,设计了独特的高低压转换回路和模具自动润滑系统,并且大量选用插装阀和使用了数字同步阀,提高了系统响应的速度和精度、改善了润滑条件。总之,本机可在自由胀形、轴压胀形、T型管件胀形、十字管件胀形等多种加工方式下进行高强度合金钢液压成形的实验验证,为今后液压塑性成形实验台的构建和数值模拟验证奠定了基础,从而加快了管材液力塑性成形技术在军事上的应用。通过数值模拟与仿真研究,优化了本机结构,验证了液压系统的可行性,为下一步实际生产与制造提供了可靠参考。更多还原

【Abstract】 Tube hydroforming technology effectively combines the character of structured light-weight with flexible processing technology. It’s a near net shape technology which belongs to special plastic forming. Thus, many developed countries have done a lot of research on the technology and gradually apply it from automotive to aerospace, military, supplies and other applications. Our research on the forming equipment, processing parameter control and model design, etc are lagging behind other countries, especially it is quite scarce in verification of computer simulation of high-alloy tube forming process. So, promoting the design and manufacture of high-alloy tube hydroforming test machine actively, and ultimately establishing a calibration verification system of tube hydroforming process is a necessary and important work.Firstly, this paper analysed the features of tube hydroforming and the largest geometric parameters of the forming parts; Then derived mathematical formula based on the free-bulge forming model with both ends fixed and non-axial feed; After that, calculated the maximum forming parameters; Finally ascertain the hydroforming experimental machine’s main technical parameters.The hydraulic experimental machine adopted four-cylinder clamping, four floating columns and auxiliary clamping structure, which increased the clamping pressure, compact structure, the effective space, and so on. It aslo adopted triple feed and balance-conversion structure, which expanded the scope of the forming. In addition, the machine realized the modular and lightweight structure, reduced its weight, and could achieve the work of multiple machines combined, and formed a large workpiece. In the hydraulic system, a unique high and low voltage conversion circuit and automatic lubrication system of model were designed, cartridge valve and the digital synchronization valve were extensively adopted. All of that was to improve the system’s efficiency, ameliorate the lubrication conditions, improve the speed and accuracy of system’s response. In short, the machine can actualize the validation of free bulging, bulging axial, T-tube forming, cross-tube bulge and other processing methods. It set up the foundation for constitution of experimental platform of hydraulic forming and numerical simulation of hydraulic forming.the structure of this machine was optimized, and the feasibility of the hydraulic system was verified by using numerical modeling and simulation, and these work will provide a reliable reference for actual production and manufacturing in future.更多还原