800MN模锻液压机本体结构分析
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摘要
巨型模锻压机是国家综合实力的一种象征，它充分体现了一个国家的大型装备制造生产能力、综合技术水平以及经济与国防实力。800MN模锻液压机是目前世界上最大的模锻液压机，它的建立可以解决大型整体结构件毛坯制造的瓶颈，促进大型模锻件制造技术的消化、吸收和创新，在国防和航空工业的模锻件生产中起着不可替代的作用，其政治、经济意义重大。由于巨型模锻压机要承受超大的载荷，因此有很高的结构强度和刚度要求，制造难度极高，造价昂贵，并且建造数量十分有限，为解决其可制造性问题，该压机采用了以组合结构为主要特征的大量新结构。为确保这一新的重型装备的一次制造成功，对该设备进行本体结构强度、刚度分析和疲劳寿命预测是一项必做的前期工作。
本文以800MN大型模锻液压机的关键承力结构C形板组合机架为研究对象，使用大型非线性有限元软件MSC. Marc从静力学角度对其应力应变及变形情况进行了分析研究；用疲劳分析软件MSC. Fatigue对及关键部件进行了疲劳寿命分析；并且制作了800MN模锻液压机机架1:25金属物理模型，用电测法对关键构件-C形板、大拉杆和上十字键在预紧和承载工况下的应力进行了测试。从数据对比来看，仿真结果与试验结果基本吻合，说明了仿真结果的可信性。论文的研究成果为800MN模锻压机的设计制造提供了理论依据。
Heavy die-forging hydraulic press is a national symbol of a country’s comprehensivestrength, because it fully shows the ability of big equipment manufacturing, the technicallevel, and the capacity of economics and national defense of a country. The press will playan irreplaceable role in forging pieces production for defense and aerospace industry. Atpresent, the 800 MN die-forging hydraulic press is the largest die-forging hydraulic pressin the world. It is required for high strength, high stiffness in the structure of the pressbecause high load will be undertaken, meanwhile the high expenses very limitedproduction quantity, and extreme manufacturing difficulties are the typical characyeristicsof this equipement. In order to build successfully, a large number of new structures, as itsmain structure characteristics, are adopted in its structure. This heavy die-forginghydraulic press has a great significance in political and economics .To ensure one-timesuccess in manufacture of the new heavy equipment, it is necessary to analyse the intensity,stiffness and fatigue life of the body structure previously.
In this dissertation, taking the main load-carrying body structure, C–form frame of800 MN die-forging hydraulic press as the research object, the stress, strain anddeformation are analysed using the large nonlinear FEM software MSC. Marc, thestructure fatigue life of key components of the body is analysed with MSC. Fatigue, ametal physical model of 1:25 of the C-frame is made and the stress of key components,such as C-plates, main prestress rods as while as the upper and lower cross keys, under thepretight and operation load. After contrast between the results from simulation andexperiments, conclusion can be made that the simulation result is credibility. The researchresult can provides theoretical support for the design and manufacturing of the 800 MNdie-forging hydraulic press.
本文以800MN大型模锻液压机的关键承力结构C形板组合机架为研究对象，使用大型非线性有限元软件MSC. Marc从静力学角度对其应力应变及变形情况进行了分析研究；用疲劳分析软件MSC. Fatigue对及关键部件进行了疲劳寿命分析；并且制作了800MN模锻液压机机架1:25金属物理模型，用电测法对关键构件-C形板、大拉杆和上十字键在预紧和承载工况下的应力进行了测试。从数据对比来看，仿真结果与试验结果基本吻合，说明了仿真结果的可信性。论文的研究成果为800MN模锻压机的设计制造提供了理论依据。
Heavy die-forging hydraulic press is a national symbol of a country’s comprehensivestrength, because it fully shows the ability of big equipment manufacturing, the technicallevel, and the capacity of economics and national defense of a country. The press will playan irreplaceable role in forging pieces production for defense and aerospace industry. Atpresent, the 800 MN die-forging hydraulic press is the largest die-forging hydraulic pressin the world. It is required for high strength, high stiffness in the structure of the pressbecause high load will be undertaken, meanwhile the high expenses very limitedproduction quantity, and extreme manufacturing difficulties are the typical characyeristicsof this equipement. In order to build successfully, a large number of new structures, as itsmain structure characteristics, are adopted in its structure. This heavy die-forginghydraulic press has a great significance in political and economics .To ensure one-timesuccess in manufacture of the new heavy equipment, it is necessary to analyse the intensity,stiffness and fatigue life of the body structure previously.
In this dissertation, taking the main load-carrying body structure, C–form frame of800 MN die-forging hydraulic press as the research object, the stress, strain anddeformation are analysed using the large nonlinear FEM software MSC. Marc, thestructure fatigue life of key components of the body is analysed with MSC. Fatigue, ametal physical model of 1:25 of the C-frame is made and the stress of key components,such as C-plates, main prestress rods as while as the upper and lower cross keys, under thepretight and operation load. After contrast between the results from simulation andexperiments, conclusion can be made that the simulation result is credibility. The researchresult can provides theoretical support for the design and manufacturing of the 800 MNdie-forging hydraulic press.
引文
[1]吴生福. 150MN锻造液压机本体组合结构研究[D].秦皇岛:燕山大学材料加工工程学科博士学位论文, 2006: 1-2.
[2]于凤仁.当代锻造液压机的发展状况与现有液压机的改装[J].重型机械, 1990(1): 11-16.
[3]王芳芳.巨型模锻压机典型组合承载结构过盈联接界面接触问题的研究与优化[D].长沙:中南大学机械设计及理论学科硕士学位论文, 2011: 1-2.
[4]杨固川,于江,陈文,等.大型模锻液压机机架结构分析研究[J].锻压技术, 2010, 35(3):109-112.
[5]俞新陆.液压机的设计与应用[M].北京:机械工业出版社, 2007: 10-12.
[6]杨振民. 45MN快锻液压机本体关键部件结构设计与分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 2-4.
[7]刘广军.液压锻造机的本体结构分析与优化[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 3-7.
[8]候晓望.基于有限元分析的液压机结构优化[D].杭州:浙江大学化工过程机械学科硕士学位论文, 2005: 7-10.
[9]第一机械工业部重型机械研究所.国内外重型锻压设备图册[M].第一机械工业部重型机械研究所, 1964 (5): 3-5.
[10] Zhang Y N, Liu S H, Wu Y L. Detailed simulation and analysis of pressure fluctuation in Francisturbine[J]. Shuili Fadian Xuebao/Journal of Hydroelectric Engineering, 2009, 12(28): 183-186.
[11] Men E M, Sheverdyaev N P. Automation of a hydraulic four-column Press [J]. Glass and Ceramics,1960, 14(5): 170-173.
[12] Attaryan V G. Modernization of the 1500-ton hydraulic press [J]. Metallurgist, 1959(8): 353-355.
[13]邓晨曦,吴任东,颜永年,等.大型承载框架钢丝预应力缠绕技术研究[J].新技术新工艺,2008(2) : 51-55.
[14]孙彩丽. 20MN快锻液压机设计及整体工作性能分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2007: 7-8.
[15]陈尚其.锻造液压机本体结构发展述评[J].重机制造, 1990(22): 23-30.
[16]彭伟波.巨型模锻液压机典型组合结构的承载与变形特性分析[D].长沙:中南大学机械设计及理论学科硕士学位论文, 2007: 3-4.
[17]吴先文. 120MN水压机技术改造研究[D].成都:西南交通大学机械工程学科硕士学位论文,2006: 6-8.
[18]刘振堂.我国锻压机械行业现状概况[J].锻压装备与制造技术, 2006(3): 28-30.
[19]韩伦. 60MN锻造水压机本体关键件结构分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 8-10.
[20]曹兴强.拉杆组预紧组合承载结构的力学建模与八万吨压机三梁结构的优化[D].长沙:中南大学机械设计及理论硕士学位论文, 2008: 12-13.
[21]张胜华.快锻液压机机架的有限元分析[D].西安:西北工业大学材料加工工程学科硕士论文, 2004: 16-21.
[22]别洛夫等著,靳辅安等译.水压机模锻[M].北京:国防工业出版社, 1981: 145-150.
[23]赵长财,袁荣娟.液压缸法兰应力集中的研究[J].锻压技术, 1994(3): 50-52.
[24]邓英剑.巨型压机主工作缸的可靠性的分析与设计[D].长沙:中南大学机械设计及理论学科硕士论文, 2007: 1-9.
[25]彭伟波,黄明辉.大型模锻液压机组合垫板有限元分析[J].机械设计制造. 2008(2): 70-72.
[26]林秀安,聂绍珉.液压机组合垫板机架的整体工作性能分析[J].机械工程学报, 1984(2):58-68.
[27]吴生富,金淼,聂绍珉,等.大型锻造液压机全预紧组合机架的整体性及影响因素分析[J].塑性工程学报, 2006, 13(2): 110-113.
[28]吴生富,聂绍珉,金淼,等.大型锻造液压机全预紧机架的整机分析[J],燕山大学学报, 2006,30(2): 134-146.
[29]吴生富,金淼,聂绍珉,等.液压机全预紧组合机架的整体性分析[J].锻压技术, 2006(3):111-115.
[30]俞新陆.液压机[M].北京:机械工业出版社, 1982: 156-159.
[31]李志波,董国疆,吴树亮,等. 12.5 MN双柱快锻液压机机架的有限元分析[J].锻压技术,2008, 33(4): 100-104.
[32]王亚军.大型结构整体建模及八万吨压机主机架分析与优化设计[D].长沙:中南大学机械设计及理论学科硕士论文, 2009: 15-18.
[33]沈鸿. 12000吨锻造水压机[M].北京:机械工业出版社, 1980: 134-152.
[34]张昭,蔡志勤.有限元方法与应用[M].大连:大连理工大学出版社, 2011: 15-16.
[35]陈火红,祁鹏. MSC.Patran/Mentat2003基础与应用实例[M].北京:科学出版社, 2004: 85-86.
[36] Borgersen S E. Simulated inflation of a vascular stent using 3-dimensional nonlinear fea contactanalysis[J]. American Society of Mechanical Engineers, 1994(28): 212-216.
[37] Buscaglia G C. Adaptive finite element approach frictionless contact problems[J]. InternationalJournal for Numerical Methods in Engineering, 2009(50): 395-418.
[38] Fullerton R D, Svendson L F. Minimum Area Rig Concept: Second Generation[C]. Proceedings ofthe Drilling Conference. 1994(8): 87-90.
[39]黄宁,黄明辉,湛利华,等.巨型压机C型机架的结构分析与改进[J].锻压技术, 2009, 34(5):93-95.
[40]姚卫星.结构疲劳寿命分析[M].北京:国防工业出版社. 2003:21-23.
[41] Zhao W M, Zhang W Z. Study on thermal fatigue life prediction of cylinder head[J]. AdvancedMaterials Research, 2012 (433-440): 3-8.
[42]张朋,李梅山.塔式起重机钢结构疲劳寿命估算[J].建筑机械, 2000(5): 42-44.
[43] Al-Khateeb G, Shenoy A. A simple quantitative method for identification of failure due to fatiguedamage[J]. International Journal of Damage Mechanics, 2011(20): 3-21.
[44]王进.基于有限元法的塔式起重机钢结构疲劳寿命研究[D].重庆:重庆大学机械设计及理论学科硕士学位论文, 2005: 25-28.
[45]李永利等著;张然治译.疲劳实验测试分析理论与实践[M].北京:国防工业出版社, 2011:68-69.
[46] Shimizu S, Tosha K, Tsuchiya K. New data analysis of probabilistic stress-life (P-S-N) curve andits application for structural materials[J]. International Journal of Fatigue, 2010(32): 565-575.
[47]陈帅.柴油机油底壳疲劳分析﹑寿命预测与优化设计方法的研究[D].武汉:武汉理工大学轮机工程学科硕士学位论文, 2011: 35-41.
[48]孙先波.基于JTP的油船结构疲劳评估方法研究[D].大连:大连理工大学船舶与海洋结构物设计制造学科硕士学位论文, 2006: 21-23
[49]黄学玲.锻压测试技术[M].北京:机械工业出版社, 1982: 87-91.
[50]沙心勇.全预紧结构液压机的整体性研究[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2011: 37-38.
[51]唐景林,马丽霞,李志明,等.预应力框架大型液压机拉杆预紧力非缓解测量研究[J].机械工程学报, 2010，46 (22): 70-74.
[2]于凤仁.当代锻造液压机的发展状况与现有液压机的改装[J].重型机械, 1990(1): 11-16.
[3]王芳芳.巨型模锻压机典型组合承载结构过盈联接界面接触问题的研究与优化[D].长沙:中南大学机械设计及理论学科硕士学位论文, 2011: 1-2.
[4]杨固川,于江,陈文,等.大型模锻液压机机架结构分析研究[J].锻压技术, 2010, 35(3):109-112.
[5]俞新陆.液压机的设计与应用[M].北京:机械工业出版社, 2007: 10-12.
[6]杨振民. 45MN快锻液压机本体关键部件结构设计与分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 2-4.
[7]刘广军.液压锻造机的本体结构分析与优化[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 3-7.
[8]候晓望.基于有限元分析的液压机结构优化[D].杭州:浙江大学化工过程机械学科硕士学位论文, 2005: 7-10.
[9]第一机械工业部重型机械研究所.国内外重型锻压设备图册[M].第一机械工业部重型机械研究所, 1964 (5): 3-5.
[10] Zhang Y N, Liu S H, Wu Y L. Detailed simulation and analysis of pressure fluctuation in Francisturbine[J]. Shuili Fadian Xuebao/Journal of Hydroelectric Engineering, 2009, 12(28): 183-186.
[11] Men E M, Sheverdyaev N P. Automation of a hydraulic four-column Press [J]. Glass and Ceramics,1960, 14(5): 170-173.
[12] Attaryan V G. Modernization of the 1500-ton hydraulic press [J]. Metallurgist, 1959(8): 353-355.
[13]邓晨曦,吴任东,颜永年,等.大型承载框架钢丝预应力缠绕技术研究[J].新技术新工艺,2008(2) : 51-55.
[14]孙彩丽. 20MN快锻液压机设计及整体工作性能分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2007: 7-8.
[15]陈尚其.锻造液压机本体结构发展述评[J].重机制造, 1990(22): 23-30.
[16]彭伟波.巨型模锻液压机典型组合结构的承载与变形特性分析[D].长沙:中南大学机械设计及理论学科硕士学位论文, 2007: 3-4.
[17]吴先文. 120MN水压机技术改造研究[D].成都:西南交通大学机械工程学科硕士学位论文,2006: 6-8.
[18]刘振堂.我国锻压机械行业现状概况[J].锻压装备与制造技术, 2006(3): 28-30.
[19]韩伦. 60MN锻造水压机本体关键件结构分析[D].秦皇岛:燕山大学材料加工工程学科硕士学位论文, 2006: 8-10.
[20]曹兴强.拉杆组预紧组合承载结构的力学建模与八万吨压机三梁结构的优化[D].长沙:中南大学机械设计及理论硕士学位论文, 2008: 12-13.
[21]张胜华.快锻液压机机架的有限元分析[D].西安:西北工业大学材料加工工程学科硕士论文, 2004: 16-21.
[22]别洛夫等著,靳辅安等译.水压机模锻[M].北京:国防工业出版社, 1981: 145-150.
[23]赵长财,袁荣娟.液压缸法兰应力集中的研究[J].锻压技术, 1994(3): 50-52.
[24]邓英剑.巨型压机主工作缸的可靠性的分析与设计[D].长沙:中南大学机械设计及理论学科硕士论文, 2007: 1-9.
[25]彭伟波,黄明辉.大型模锻液压机组合垫板有限元分析[J].机械设计制造. 2008(2): 70-72.
[26]林秀安,聂绍珉.液压机组合垫板机架的整体工作性能分析[J].机械工程学报, 1984(2):58-68.
[27]吴生富,金淼,聂绍珉,等.大型锻造液压机全预紧组合机架的整体性及影响因素分析[J].塑性工程学报, 2006, 13(2): 110-113.
[28]吴生富,聂绍珉,金淼,等.大型锻造液压机全预紧机架的整机分析[J],燕山大学学报, 2006,30(2): 134-146.
[29]吴生富,金淼,聂绍珉,等.液压机全预紧组合机架的整体性分析[J].锻压技术, 2006(3):111-115.
[30]俞新陆.液压机[M].北京:机械工业出版社, 1982: 156-159.
[31]李志波,董国疆,吴树亮,等. 12.5 MN双柱快锻液压机机架的有限元分析[J].锻压技术,2008, 33(4): 100-104.
[32]王亚军.大型结构整体建模及八万吨压机主机架分析与优化设计[D].长沙:中南大学机械设计及理论学科硕士论文, 2009: 15-18.
[33]沈鸿. 12000吨锻造水压机[M].北京:机械工业出版社, 1980: 134-152.
[34]张昭,蔡志勤.有限元方法与应用[M].大连:大连理工大学出版社, 2011: 15-16.
[35]陈火红,祁鹏. MSC.Patran/Mentat2003基础与应用实例[M].北京:科学出版社, 2004: 85-86.
[36] Borgersen S E. Simulated inflation of a vascular stent using 3-dimensional nonlinear fea contactanalysis[J]. American Society of Mechanical Engineers, 1994(28): 212-216.
[37] Buscaglia G C. Adaptive finite element approach frictionless contact problems[J]. InternationalJournal for Numerical Methods in Engineering, 2009(50): 395-418.
[38] Fullerton R D, Svendson L F. Minimum Area Rig Concept: Second Generation[C]. Proceedings ofthe Drilling Conference. 1994(8): 87-90.
[39]黄宁,黄明辉,湛利华,等.巨型压机C型机架的结构分析与改进[J].锻压技术, 2009, 34(5):93-95.
[40]姚卫星.结构疲劳寿命分析[M].北京:国防工业出版社. 2003:21-23.
[41] Zhao W M, Zhang W Z. Study on thermal fatigue life prediction of cylinder head[J]. AdvancedMaterials Research, 2012 (433-440): 3-8.
[42]张朋,李梅山.塔式起重机钢结构疲劳寿命估算[J].建筑机械, 2000(5): 42-44.
[43] Al-Khateeb G, Shenoy A. A simple quantitative method for identification of failure due to fatiguedamage[J]. International Journal of Damage Mechanics, 2011(20): 3-21.
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