【摘要】：在軌道交通、公路客車、廂式貨車等領(lǐng)域,采用全鋁結(jié)構(gòu)制造車體成為實(shí)現(xiàn)輕量化的一種必然趨勢。隨著大型整體空心復(fù)雜薄壁型材擠壓技術(shù)及焊接技術(shù)的成熟,大型鋁構(gòu)件得到了廣泛的推廣與應(yīng)用。近年來,我國高速列車技術(shù)得到了飛速發(fā)展,但在車體加工制造領(lǐng)域卻存在著短板,機(jī)加工所用的大型裝備仍然主要依賴于進(jìn)口。針對于大型鋁構(gòu)件特點(diǎn)和加工工藝特點(diǎn)的國產(chǎn)加工中心研究相對落后,加工效率低下、高速驅(qū)動及動態(tài)穩(wěn)定性等問題解決不徹底,在高速列車加工制造領(lǐng)域國產(chǎn)設(shè)備往往只用于輔助工序,這大大增加了車體加工的成本,降低國產(chǎn)高速列車在世界上的競爭力。因此研究開發(fā)具有自主知識產(chǎn)權(quán)的、適用于鋁合金車體及其大型鋁構(gòu)件的加工機(jī)床具有重要意義。 本課題研究的加工中心是根據(jù)動車車體及大型鋁構(gòu)件結(jié)構(gòu)特點(diǎn)、工藝特點(diǎn),在繼承傳統(tǒng)金屬切削龍門加工中心基本特點(diǎn)的基礎(chǔ)上創(chuàng)新設(shè)計(jì)而成。對關(guān)鍵部件進(jìn)行了輕量化設(shè)計(jì),提高快移速度,同時(shí)通過拓?fù)鋬?yōu)化設(shè)計(jì)提高了橫梁的靜動態(tài)特性,解決高速運(yùn)行帶來的動態(tài)穩(wěn)定性問題。 根據(jù)加工中心的設(shè)計(jì)要求,采用模塊化設(shè)計(jì)基本原理和功能分析法實(shí)現(xiàn)機(jī)床的總體方案設(shè)計(jì),一次裝夾可實(shí)現(xiàn)銑、鉆、鏜、擴(kuò)、鉸及鋸切等加工�；谀K化設(shè)計(jì)的分離式立柱可快速更換,便于調(diào)整加工中心的Z向行程,同時(shí)降低了裝配難度。對X/Y/Z向的直線驅(qū)動系統(tǒng)進(jìn)行了設(shè)計(jì),介紹了雙電機(jī)伺服消隙系統(tǒng)的基本工作原理。 對原始的橫梁方案進(jìn)行了靜動態(tài)特性分析,并對關(guān)鍵結(jié)合面進(jìn)行了建模。立柱的螺栓結(jié)合面采用虛擬材料模型,通過計(jì)算獲取了虛擬材料層的彈性模量、泊松比和密度；導(dǎo)軌結(jié)合面采用彈簧阻尼單元模型,獲取了彈簧單元的剛度系數(shù)。在有限元建模過程引入了結(jié)合面的參數(shù),分別研究了受重力和切削力的工況下,刀頭沿Z向的位移變形情況,并分析了橫梁的前6階固有頻率。 基于拓?fù)鋬?yōu)化方法對橫梁結(jié)構(gòu)進(jìn)行輕量化設(shè)計(jì),提高橫梁的動態(tài)性能,降低高速運(yùn)行產(chǎn)生的振動。在Hypermesh中建立橫梁及其組件的有限元模型并設(shè)置優(yōu)化目標(biāo)函數(shù)、約束函數(shù)以及邊界條件�；谧畲髣偠仍O(shè)計(jì)的拓?fù)鋬?yōu)化模型和特征值問題的結(jié)構(gòu)動力學(xué)拓?fù)鋬?yōu)化模型,對初始的橫梁結(jié)構(gòu)進(jìn)行了改進(jìn),提高了整體剛性和固有頻率,同時(shí)實(shí)現(xiàn)了橫梁的輕量化設(shè)計(jì)。 本課題得到2012年山東省科技發(fā)展計(jì)劃(項(xiàng)目編號：2012GGE27113)資助。
[Abstract]:In the fields of rail transit, highway passenger cars, van trucks and so on, the manufacture of car bodies with all-aluminum structure has become an inevitable trend to achieve lightweight. With the maturity of extrusion technology and welding technology of large integral hollow and complex thin-wall profiles, large aluminum components have been widely popularized and applied. In recent years, high-speed train technology in China has been developed rapidly, but there are shortcomings in the field of car body processing and manufacturing, and the large-scale equipment used in machining still mainly depends on imports. In view of the characteristics of large aluminum components and processing technology, the research of domestic machining center is relatively backward, the machining efficiency is low, and the problems of high speed drive and dynamic stability are not solved completely. In the field of high-speed train processing, domestic equipment is often only used in auxiliary processes, which greatly increases the cost of car body processing and reduces the competitiveness of domestic high-speed trains in the world. Therefore, it is of great significance to research and develop machine tools with independent intellectual property rights, which are suitable for aluminum alloy car body and its large aluminum components. According to the structural and technological characteristics of the car body and large aluminum components, the machining center studied in this paper is designed on the basis of inheriting the basic characteristics of the traditional metal cutting gantry machining center. The lightweight design of the key components is carried out to improve the fast moving speed. At the same time, the static and dynamic characteristics of the beam are improved by topology optimization design, and the dynamic stability problem caused by high speed operation is solved. According to the design requirements of the machining center, the basic principle of modular design and functional analysis method are used to realize the overall scheme design of the machine tool. The milling, drilling, boring, expansion, hinge and sawing can be realized by one clamping. The separated column based on modular design can be replaced quickly, which is convenient to adjust the Z-direction stroke of the machining center and reduce the assembly difficulty at the same time. The linear drive system in X/Y/Z direction is designed, and the basic working principle of double motor servo gap elimination system is introduced. The static and dynamic characteristics of the original beam scheme are analyzed, and the key joint is modeled. The elastic modulus, Poisson's ratio and density of the virtual material layer are obtained by calculating the bolt joint surface of the column, and the stiffness coefficient of the spring element is obtained by using the spring damping element model on the guide rail joint surface. In the finite element modeling process, the parameters of the joint surface are introduced, and the displacement and deformation of the cutter head along the Z direction under the conditions of gravity and cutting force are studied respectively, and the natural frequencies of the first six orders of the crossbeam are analyzed. Based on the topology optimization method, the light weight design of the beam structure is carried out to improve the dynamic performance of the beam and reduce the vibration caused by high speed operation. The finite element model of beam and its components is established in Hypermesh, and the optimization objective function, constraint function and boundary condition are set up. Based on the topological optimization model of maximum stiffness design and the structural dynamic topological optimization model of eigenvalue problem, the initial beam structure is improved, the overall rigidity and natural frequency are improved, and the lightweight design of crossbeam is realized at the same time. This project is supported by Shandong Science and Technology Development Plan 2012 (Project No.: 2012GGE27113).
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2014
【分類號】：TG659

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