双锻造操作机大车行走系统控制方法探析

双锻造操作机配合压机联动完成大型高精长轴类锻件的锻造,可以有效提高锻造效率,提升锻件品质。针对双操作机夹持锻件同步行走控制难题,以燕山大学的两台20 kN锻造操作机为研究对象,综合考虑了吊挂系统、大车行走机械和液压系统的特点,搭建了双锻造操作机大车行走系统的数学模型。在此基础上,仿真研究了独立反馈位置同步控制方法、位置速度复合独立反馈同步控制方法和位置速度复合状态差值校正同步控制方法对双操作机大车行走系统控制特性的影响。仿真结果表明,对于动力性能差异较大的两台重载机械手,基于位置速度复合状态差值校正同步控制方法的控制效果最为理想,同时设定操作机A和操作机B的给定位移200 mm、加速度1000 mm/s2时,双操作机大车行走系统的动作响应时间为105 s,同步位置误差为［-0.28 mm,0.02 mm］。研究结果可为双锻造操作机控制提供技术支撑和理论指导,对于提升锻造产品质量和实现锻造生产线的智能控制具有重要意义。     

平行连杆式操作机悬挂系统刚度与阻尼参数研究

为合理设计操作机悬挂系统的缓冲装置以减小惯性冲击的影响,针对平行连杆式锻造操作机,简化了设备模型,分析了制动工况下悬挂系统各杆件的受力状态和运动规律,并利用牛顿-欧拉法综合各杆件的动力学分析,建立了悬挂系统在制动时的动力学模型,提出了缓冲装置刚度及阻尼参数确定的思路。以300kN锻造操作机为例,在MATLAB中求解操作机悬挂系统动力学微分方程,分析了缓冲刚度、阻尼对吊杆摆角、钳杆质心运动规律的影响。结果表明,利用牛顿-欧拉法建立模型确定缓冲刚度与阻尼参数的方法是可行的与合理的,从而为平行连杆式操作机悬挂系统缓冲装置的刚度与阻尼设计提供了理论依据。     

Prediction of dimensional errors in 3D complex shapes due to press elasticity

This paper presents an approach to predict dimensional errors in 3D complex shapes due to press geometry errors and elasticity. Using a press stiffness matrix formulation for the press deflections in forging operation, a quantitative relationship between forging die deviations and the press geometry errors and elastic deflections is developed, which is a function of the forging force, press stiffness and the spatial relationship between the forging dies and the press table. The stiffness matrix of a screw press is obtained using finite element analysis. To evaluate the effect of the press elasticity on dimensional errors of 3D components, a case study of forging for aerofoil shapes is carried out based on the results from physical modelling experiments. With the representative information of the tool shape and forging force data, numerical results of the forging die deviations as a source of dimensional errors for the aerofoil shape are obtained and evaluated. It is demonstrated that this approach is applicable to forging and other metal forming processes for complex shapes.     

完全解耦式锻造操作机运动机理与动力学

为了实现锻造操作机升降运动与水平移动之间的解耦,提出了一种从结构组成原理上实现解耦的锻造操作机机构,并对该机构的运动机理和动力学性能进行了研究与实验验证。首先,基于Hoekens四连杆机构介绍了完全解耦式锻造操作机的结构组成原理;运用螺旋理论工具分析了完全解耦式操作机机构的自由度,对其升降运动和水平移动之间的解耦机理进行了剖析。然后,基于虚功原理建立了操作机机构动力学模型,比较分析了该解耦式操作机机构和典型平行连杆式操作机机构在升降运动和锻造加工过程中的受力性能。最后,研制了该新型解耦式操作机的比例实验模型,采用激光跟踪仪测试了钳杆在升降过程中的水平位移变化量。实验结果表明:在升降运动过程中,钳杆在水平方向的位移变化量在1mm之内,基本上验证了该完全解耦式锻造操作机能够实现升降运动与水平移动之间的解耦。     

汽车前轴精密辊锻成形过程的数值模拟

汽车前轴的精辊-模锻工艺是一种用小成形力锻造设备成形较大型前轴锻件的塑性加工技术,其工艺关键在于精密辊锻。前轴的精密辊锻分4个道次,是典型的局部成形工艺。辊锻工艺由于旋转的模具与辊锻件之间的接触区域在不断变化,一直以来成为数值模拟的难点。对4个道次的模具建立了模型,采用三维刚塑性有限元程序DEFORM-3D模拟了前轴精密辊锻工艺,分析了辊锻过程中金属变形的规律,研究了模具参数对成形质量的影响以及辊锻力矩的变化规律。模拟结果对于改进辊锻工艺设计、提高模具设计水平具有指导作用。     

机械系统典型运动过程动态分析与数字仿真

以锻造机械手典型机械运动（如水平直线运动和旋转运动）为例，建立该运动过程的动态数学模型，通过变参数仿真研究各参数对系统动态特性的影响，并分析了系统响应特性对控制系统及控制精度的影响。对于提高大型复杂机械系统的控制精度具有参考价值。     

Prediction of contact pressure, slip distance and wear in cold rotary forging using finite element methods

This paper aims to utilize finite element (FE) methods to predict the wear of dies and workpiece in cold rotary forging through systematically investigating the contact pressure and the contact slip distance. For this purpose, a 3D elastic-plastic FE model of cold rotary forging is developed using the FE code ABAQUS. Using this reliable 3D FE model, the evolution and the distribution of contact pressure and contact slip distance are investigated in detail. Consequently, a new insight into the wear that occurs at the surfaces of the dies and the workpiece is gained based on Archard's wear law.     

Prediction of contact pressure,slip distance and wear in cold rotary forging using finite element methods

This paper aims to utilize finite element (FE) methods to predict the wear of dies and workpiece in cold rotary forging through systematically investigating the contact pressure and the contact slip distance. For this purpose, a 3D elastic-plastic FE model of cold rotary forging is developed using the FE code ABAQUS. Using this reliable 3D FE model, the evolution and the distribution of contact pressure and contact slip distance are investigated in detail. Consequently, a new insight into the wear that occurs at the surfaces of the dies and the workpiece is gained based on Archard's wear law.     

5_DOF取皿机械臂设计与虚拟样机仿真

根据微生物培养过程中需对培养皿抓取和分拣的工作要求,设计了一款5自由度小型机械臂,通过UG软件建立其三维模型。利用D-H法建立其连杆坐标系并作运动学分析。采用MATLAB建立机械臂数学模型并对其工作空间进行分析与验证。将该三维模型导入到ADAMS软件中进行运动学/动力学仿真分析,得出机械臂各关节角速度、力矩等参数曲线,仿真结果可为该机械臂的物理样机制造与取放皿操作实验提供参考。     

Die-Workpiece Interfacial Behaviors in Axisymmetric Forging Processes with Flat Dies

A new piezo-viscous, average flow model combined with an advanced slab method is used to investigate the lubrication in axisymmetric forging processes with flat dies. Interactions between lubricant transport and surface roughness are studied. Influence of friction on the outward motion of the workpiece is also considered. It is shown that the lubricant is transported outward in a speed slower than half the surface speed, and the film thickness is smaller than the case of the smooth surface if asperity contact is not severe. However, when asperity contact is pronounced, the lubricant pressure distribution is quite different from the prior research. Mixed lubrication is observed in most of the region where asperity contact occurs. Boundary lubrication can only be found in a narrow area near the workpiece edge.     

重载锻造操作机夹持力研究

对重载锻造操作机夹持力计算的重要性和困难性进行分析,指出钳口表面有别于一般意义上的机械手夹持面。并将夹持装置钳口与锻件接触面之间简化为钳口凸齿与锻件挤压槽的作用,提出一种夹持力计算的思路。根据使用工况,将钳口工作分为夹紧状态和夹持状态,阐述两种状态的工作特点和作用,建立工件夹持状态下的受力模型,计算夹持状态下钳口在水平和垂直两个位置时的夹持力。用放大系数修正后的夹持力确定钳杆夹紧液压缸输出力,实现夹紧状态时钳口与工件之间形成充分的凹凸齿作用,以保证钳口夹持状态时能够输出最大夹持力矩。结合钳口与工件接触表面的结构特点和作用,提出钳口凸齿设计的思路和原则。实例计算和虚拟样机仿真证明计算结果有效。     

巨型模锻液压机同步控制系统建模及仿真

为了提高巨型模锻液压机同步控制系统的快速响应性,在300MN模锻液压机的基础上,针对800MN模锻液压机的特点重新设计了同步控制系统,并基于液压基础理论和动力学理论,联合建立了活动横梁运行时同步控制系统的整体数学模型。将原方案和现有方案进行了对比仿真,结果表明:新设计的800MN同步控制系统的响应特性较原方案的响应特性有较大幅度的改善,响应速度和动静态精度均有较大提高。     

四自由度锻造操作手模拟实验台动力学建模与控制

锻造操作手在时变工况下的动力学特性直接影响着锻件的成形质量.采用拉格朗日方程法建立四自由度锻造操作手模拟实验台动力学模型,并将数学模型与ADAMS虚拟样机的动力学仿真结果进行对比验证,证明了模型的合理性.在此基础上,设计基于重力补偿的PID控制器,仿真结果显示控制性能良好.研究结果为实际锻造操作手的动力学研究和轨迹规划提供了有价值的参考.     

Complete dynamic modeling and approximate state space equations of the flexible link manipulator

This work treats the problem of dynamic modeling and state space approximation for robotic manipulators with flexibility. Case studies are planar manipulators with a single flexible link together with clamped-free ends and tip mass conditions. In this paper, complete dynamic modeling of the flexible beam without premature linearization in the formulation of the dynamics equations is developed, whereby this model is capable of reproducing nonlinear dynamic effects, such as the beam stiffening due to the centrifugal and the Coriolis forces induced by rotation of the joints, giving it the capability to predict reliable dynamic behavior. On the other hand, in order to show the joint flexibility effects on the model dynamic behaviors, manipulator with structural and joint flexibility is considered. Thus, a reliable model for flexible beam is then presented. The model is founded on two basic assumptions: inextensibility of the neutral fiber and moderate rotations of the cross sections in order to account for the foreshortening of the beam due to bending. To achieve flexible manipulator control, the standard form of state space equations for a flexible manipulator system (flexible link and actuator) is very important. In this study, finite difference method for discretization of the dynamic equations is used and the state space equations of the flexible link with tip mass considering complete dynamic of the system are obtained. Simulation results indicated substantial improvements on dynamic behavior and it is shown that the joint flexibility has a considerable effect on the dynamic behavior of rotating flexible arm that should not be simply neglected. The effects of tip mass is proved to be increasing the elastic deformations?? amplitudes and increasing stability.     

Impedance analysis of forging process and strategy study on compliance for forging manipulator

In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.     

圆柱内壁件下压装配机械手结构实现及弹簧参数优选

根据特定产品生产工艺要求,设计了一种用于圆柱内壁件作业的内撑式抓取与下压装配机械手。该机械手在手指系统与筒状手掌之间采用弹性连接。在高速作业过程中,这类弹性连接形成手指系统的残留振动。在对机械手结构设计思想与结构介绍的基础上,对机械手系统采用Adams运动仿真,分析了弹簧系统参数对手指系统的残留振动的影响,并对影响机械手振动特性的关键参数——连接弹簧的参数进行了优化选择。实际机械手的运行结果表明,该机械手结构与弹性参数的选择可以很好地满足特定对象的作业要求。     

柔性机械臂结构-控制耦合特征的实验研究

利用柔性机械臂主动控制实验装置以及相应的动力学参数测试系统 ,采用光电编码器、加速度计和应变片分别检测柔性臂的大范围运动、末端振动及驱动力矩 ,对柔性机械臂结构 -控制耦合特性进行了研究。实验结果发现 :1)由于结构与控制系统的耦合 ,改变了柔性机械臂的第一阶振动频率 ;2 )在实现规定运动时 ,不同结构的柔性机械臂的驱动力矩形式明显不同 ;3)柔性机械臂的驱动力矩具有随伺服驱动系统工频的脉动现象。验证了柔性机械臂结构与控制系统之间存在相互作用 ;指出采取结构 -控制一体化设计方法是提高柔性机械臂性能的一个重要手段。     

开式变量泵控快锻油压机系统能耗特性实验研究

针对传统自由锻造油压机泵控系统发热大以及功率回收率较低等问题,提出了开式变量泵控快锻油压机系统,并根据系统的能量流流动状态,进行了能耗建模分析。以0.6 MN泵控油压机实验平台为依托,进行了常锻工况和快锻工况下的能耗特性实验研究, 得出了常锻工况下的能耗分布规律。实验结果表明：常锻工况下的有用功占系统能耗的50%,其有用功所占比值随负载力的增大而提高;快锻工况下的有用功占系统能耗的40%以上,其有用功所占比值随锻造频率的增大而提高;开式变量泵控快锻油压机系统具有较大的节能优势。     

Comparison between cold rotary forging and conventional forging

Cold rotary forging is an innovative incremental metal forming process, which is obviously different from the conventional forging process in many aspects, such as the metal flow, degree of inhomogeneous deformation of workpiece and force and power parameters. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified by the experiment. Based on the reliable 3D FE model, the cold rotary forging and conventional forging process are simulated and their difference in the forming process has been thoroughly clarified. The research results may help to understand the cold rotary forging process better. Furthermore, they provide valuable guidelines for further theoretical analysis and experimental studies on the cold rotary forging process.     

拔长工艺中锻造操作机液压系统能耗分析

扩展了锻造操作机整机的能量流模型和能耗计算模型,研究了拔长工艺下锻造操作机液压系统的控制特性和能耗特性,得出了液压系统的能耗分布规律,分析了能量浪费的关键环节,为锻造操作机液压控制系统的优化以及节能控制方法的提出提供指导。研究结果表明,锻造操作机液压系统的能耗特性具有如下特点：夹钳上升和旋转动作的能量传递效率较高,均可达60%以上;大车行走动作的能量传递效率仅为17%;夹钳下降时重力势能几乎全部转化为升降控制阀的节流损失;多执行器不同负载与单压力源不能合理匹配会造成巨大的节流损失。