铝型材挤压机液压部分的设计【铝型材挤压机液压系统的设计及研究】
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铝型材挤压机液压系统的设计及研究
铝型材挤压机液压部分的设计【铝型材挤压机液压系统的设计及研究】
铝型材
挤压
液压
部分
设计
系统
研究
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附录 外文文献原文 A hydraulic high-speed tryout press for the simulation of mechanical forming processesAbstractThe tryout of dies plays an important part in the manufacturing of dies and in the production process in general. Despite CAD simulations, the tryout of new dies still requires a lot of time and work. Very often the time-consuming tests are conducted on expensive production lines because the presses used in the die shop, due to their different characteristics, are not suitable to reproduce the exact characteristics of the production presses. The same conditions apply after die change or after repairs of dies. Much time is consumed before the smooth production of perfect parts is possible and this, in turn, affects the productivity and the efficiency of the production equipment. As the number of die change-over operations increases together with the reduction of lot sizes caused by the increase of car model variety, shortening the time of adjustment work offers a large potential of cost saving. This is where the Schuler SMG high-speed tryout press offers immense advantages. Author Keywords: Hydraulic high-speed tryout press; Simulation; Reproducibility; Speed profile; Development; Press characteristics; Forming behaviour; Die; Drawing; Spotting; Slide tilting; Drive system; Cost and time savings Article Outline1. Introduction 2. Hydraulic high-speed tryout press 3. Slide speed profile 4. Slide tilting 5. Drive systems 6. Efficiency 7. Example of hydraulic high-speed tryout press1. IntroductionThe new generation of Schuler SMG hydraulic high-speed simulation presses is capable of reproducing the production process in the early die development stage and under conditions almost identical to the existing production conditions. This is possible due to the good reproducibility of the relevant press characteristics. The parameters obtained during simulation on the tryout press (e.g., speeds and die cushion characteristics) can be directly transferred to the production press. The die tryout on hydraulic high-speed presses shortens considerably the time that is needed for testing the dies in the production press (Fig. 1). Fig. 1. Die maker during die tryout on the hydraulic high-speed press. 2. Hydraulic high-speed tryout press The focus of the new innovative press concept was the tryout of production dies in the production environment. The main task was the consideration of mechanical production presses and their specific features. The relevant press characteristics of the simulation press must correspond to the production press characteristics. The most important features are the speed characteristics of the slide motion and the slide tilting values, the behaviour of die cushions and the static press values (the deflection of the bolster and slide, the deformation of press uprights). Result of the development was the new generation of hydraulic high-speed tryout presses. These presses have the ability to simulate the forming behaviour of different mechanical press types and brands with various drive systems and specific characteristics of slide motion. One single Schuler SMG hydraulic high-speed tryout press can cover the die tryout for a wide range of production presses, and can therefore substitute for all the previously required conventional tryout presses. In addition to the simulation of the loads and motions of mechanical presses, the hydraulic high-speed press offers the flexibility and advantages of conventional hydraulic tryout presses such as: (i) accurate load adjustments; (ii) maximum load over the whole press stroke possible; (iii) easy adjustment of stroke and die space (BDC and TDC); (iv) teach in function for all relevant switch points; (v) inching mode for the slide; (vi) reversal function at any point of the stroke; (vii) die spotting mode controlled by joystick; (viii) flexible slide locking system over the whole stroke; (ix) low maintenance costs. The hydraulic high-speed tryout press can be equipped with various peripheral equipment such as moving bolsters, bed and slide cushions with one- or multi-point control, blankholder (for double action press), rotating slide plate, external die lifters and turning stations and quick die change systems (Fig. 2). Fig. 2. High-speed tryout press with accumulator drive, four-point cushion, parallelism control, die cushion pre-acceleration and slide stroke limitations. Modern control technology is available for process monitoring, data saving and data transfer of the parameters obtained during tryout. 3. Slide speed profile The speed profile of the Schuler SMG hydraulic high-speed tryout press is freely programmable. The data of a knuckle joint or eccentric press is entered in a spreadsheet (crankshaft to slide position and slide stroke) on the control of the high-speed tryout press. Dependent on the number of strokes to be simulated, the effective slide speeds are adjusted by the control system. The slide speed is infinitely adjustable to any stroke profile of the mechanical slide motion by a highly dynamic servo-hydraulic system and a separate high-performance control circuit (servo-control valves). With the use of hydraulic accumulators, slide speeds of 500mm/s and higher can be reached. This ensures that the slide profile of the drawing station and the follow-up forming stations of mechanical production presses can all be simulated. Furthermore, the impact on the mechanical production presses which are equipped with pre-accelerated die cushions can be simulated, even without requiring die cushion pre-acceleration on the tryout press (Fig. 3). However, for exact simulation of the blank behaviour prior to the impact, a pre-accelerated die cushion is recommended. Fig. 3. Pressure profile of high-speed tryout press with and without a pre-accelerated die cushion. The motion profile of mechanical production presses can be exactly simulated. The motion sequence on a high-speed tryout press is as follows: (1) rapid approach; (2) braking up to a predefined position (stroke-dependent); (3) switch-over to working speed and start of simulation; (4) end of simulation in BDC; (5) pressure relief and slide retraction. The possible slide retraction speed is between 300 and 500mm/s. Therefore the undesired effect of vacuum sticking of the drawn part due to the quick slide retraction can be simulated during the slide retraction. Following such tests, required aeration holes can be made at an early die production stage. The whole speed and force profile of the slide can be visualised on the control screen (selected profile and performed profile). 4. Slide tilting The slide tilting values of mechanical presses are dependent on the load eccentricity and the press force. The connecting rods bear the main load to keep the slide parallel to the bolster. The slide guiding must only compensate for low forces. Due to the compression of the oil columns in the pressure cylinders, slide parallelism on hydraulic presses depends much more on the slide guiding. In order to achieve similar tilting values as on mechanical presses, the guiding system and the press uprights must be designed accordingly. Larger tilting values can only be compensated for by the use of active parallelism control systems in the xx and yy directions. Advantage of such a system: tilting values of mechanical presses can be pre-set and simulated. This is especially beneficial for large sheet panels (e.g., side panel tools) where higher eccentric loads can be expected. For the spotting of dies, adjustable mechanical slide stroke limitations are used which eliminate any slide tilting during tool contact. The sensitive die spotting control by joystick enables the closing of dies with reduced force and a controllable closing speed in the range 535mm/s. 5. Drive systems The drive system of a Schuler SMG high-speed tryout press is based on accumulator technology. Nitrogen cylinders supply energy to piston accumulators which deliver the oil to the slide cylinders. The valves for speed control are located between the piston accumulators and the slide cylinders. As an example, a press with 20000kN capacity requires only a main drive rating of 250kW. The standard design of accumulators and charging pump is suitable for approximately two simulation strokes per minute. The tryout press can be designed for up to approximately 30000kN maximum press capacity. 6. Efficiency The purpose of using hydraulic high-speed presses for tryout is the saving of production capacities or, in other words, the reduction of tryout time on the production presses. A mechanical tryout press can only simulate the production press for which it was designed in terms of slide speed characteristic (drive system) and drawing cushion system. Although the transferability of the results is even better, the machine costs are much higher than for hydraulic tryout presses. Furthermore, one hydraulic high-speed tryout press can simulate the forming behaviour of different press brands and press types (hydraulic or mechanical) with different characteristics of slide motion (Fig. 4). Fig. 4. Example of time and cost saving with hydraulic high-speed tryout presses compared with conventional hydraulic presses. For an ordinary die for side panels, the tryout time needed in the production press can be up to 6 weeks. Experiences have shown that this time can be shortened by up to 80% using the high-speed tryout presses described above. The amortisation time is rather short considering the various applications of these presses, especially when taking into account the high-hourly rates of mechanical crossbar and GT-presses of up to $3000. 7. Example of hydraulic high-speed tryout press The Schuler SMG hydraulic high-speed tryout presses shown in Fig. 5 were built for an American automobile manufacturer. Each press has a capacity of 18000kN and is equipped with moving bolster, rotating slide plate, four-point controlled pre-accelerated die cushion, stroke limitations and hydraulic die clamping system. Fig. 5. Hydraulic high-speed tryout presses with moving bolster and rotating slide plate. The slide motion profiles and slide speeds, the die cushion set-up and the mechanical characteristics ensure that an almost identical simulation of the production conditions of mechanical large-panel crossbar presses can be made. A highly sophisticated control system allows comfortable input of the variable target data, direct monitoring of the tryout process with digital and graphic display of the relevant parameters, data storage and data transfer. 附录 外文文献翻译用于机械成型加工模拟的液压高速冲压机摘要模具的试验在模具的制造业和常规生产过程中起重要作用。尽管有了CAD仿真,新模具的试验仍然需要很多时间和工作。费时的测试经常受昂贵的生产线约束，因为他们不同的特性导致在制模工厂使用的冲压机不能提供反复生产产品所需压力的精确特性。同样的情形也存在于模具改革和模具修复中。很有可能在比较完善的产品生产之前就已经花费了很多时间了，这反过来又影响生产力和生产设备的效率。伴随着汽车模型品种增加引起的规模缩减，模具彻底改革的次数也增加了，从而缩短调整工时，为成本的减少提供了很大的潜力。这是Schuler SMG 高速试验冲压机具有的特大优点。作者主题词：液压高速试验冲压机；仿真；反复生产能力；速度曲线；发展；压力特性；成形；模具；冲压成形；点位；导轨倾斜；驱动系统；节约成本和时间文章大纲 1介绍2液压高速试验冲压机3滑动速度曲线4导轨倾斜5驱动系统6效率7液压高速试验冲压机实例 1.介绍 在早期的模具发展阶段，或者在与现有的生产条件几乎相同的情况下，Schuler SMG的新一代液压高速模拟冲压机能够再现生产过程。这可能是归因于相关压力特性的良好再现能力。这些参数是在液压高速试验冲压机的模拟期间获得的(即，速度和模具缓冲装置特性)，而且它们可以直接转换成生产所需压力。对液压高速冲压机的试验很大程度上缩短了在生产冲压机过程中测试模具所花的时间(如图1)。2.液压高速试验冲压机新型创新冲压机概念的焦点在于生产环境中模具产品的试验。其主要任务是考虑机械式冲压机及其特殊性能。模拟冲压机的相关压力特性必须与成品冲压机的相关特性一致。其中，最重要的特点是滑动的速度和导轨的倾斜值，还有模具缓冲装置的性能和静态压力值(模垫和导轨的偏斜,冲压机立柱的变形)。随着技术发展，就出现了新一代液压高速试验冲压机。这些冲压机能够模拟不同机械式冲压机类型的成形性能，而且能够与各种各样的驱动系统及导轨运动的特殊参数吻合。单一的一台Schuler SMG液压高速试验冲压机能够大范围地代表模具试验的结果，所以也就代替所以的早先需要的传统试验冲压机。除了对机械式冲压机的装载和运动进行模拟之外，液压高速冲压机也具有传统试验冲压机的灵活性和优点，例如：(i) 精确装载调节；ii) 整个冲压机行程中允许的最大载荷；(iii) 调整行程和型腔的简便性(BDC 和TDC)；(iv) 所有相关转换节点的提示功能；(v) 滑动的缓进给模型；(vi) 冲程中任意点的逆转功能；(vii) 由操纵杆控制的模型定位模式；(viii) 在整个冲程中灵活的制动装置；(ix) 低维修费用。液压高速试验冲压机能够配以各种各样的外部设备，譬如可移动的模垫，床身和一点或多点控制的导轨垫，压边导轨(双动压力机),可转动的导轨，外部拔模装置，回转站和模具快速切换系统(如图2)。在试验期间，现代控制技术对于程序控制、数据保存和所得参数的转换是有效的。3.滑动速度曲线Schuler SMG液压高速试验冲压机的速度曲线是可以通过编程自由控制的。在控制高速试验冲压机时，精压机和离心冲压机的数据是在一个电子数据表输入的(曲轴滑动的位置和滑动冲程)。由于取决于模拟的冲程数目，那就可以通过控制系统有效的滑动速度。通过一个高度动态的液压伺服系统和一个独立的高性能控制电路(伺服操纵阀门)，对于机械式滑动的任意冲程曲线，滑动的速度就可以无限地调整了。随着液压蓄能器的使用，可以达到500mm/s或者更高的速度。这就确保了冲压成形站的滑动曲线和接下来的机械成品冲压机的成型站均能被模拟。而且，配有预加速的模具缓冲装置的机械成品冲压机的冲击就可以进行仿真了(如图3)。但是,在进行坯件性能的精确仿真之前，建议对模具缓冲装置预加速。高速试验冲压机的运动序列如下：(1) 快捷方法；(2) 对预定义的位置制动(由冲程决定)；(3) 转换到工作速度并开始仿真；(4) 在BDC中仿真结束；(5) 压力曲线和导轨升降。导轨允许的升降速度在300500mm/s之间。所以在导轨升降过程中，导轨快速升降引起的真空粘附的干扰影响也能够模拟了。经过这样的测试以后，就可以在模具生产的早期阶段制造所需的排气孔。到轨的整体速度和受力曲线可以控制屏上显示(精选的曲线和执行曲线)。4.导轨倾斜机械式冲压机的导轨倾斜值取决于加载偏心度压力值。连接杆承担主要载荷以保持导轨平行于压床垫板。导轨引导只须在低压时给予补偿即可。在压力圆筒中由于油柱的压缩，在液压冲压机中，导轨的平行性更加取决于导轨引导。为了达到和机械式冲压机相类似的倾斜值，必须相应地设计引导系统和冲压机立柱。如果需要更大的倾斜值，那就得通过使用xx和y-y方向平行性自动控制系统来补偿实现。这样一个系统的好处有：机械式冲压机的倾斜值可以预先进行设定并进行模拟。对于期望具有更高偏心度载荷的大薄板工件来说，这就特别有利了(即，侧板工具)。对于模具定位，使用了可调机械式导轨冲程限制，这样，在与冲头接触时就可以消除任意的导轨倾斜值。由控制杆控制的灵敏的模具定位控制，能够用较小的力使模具闭合，而且在5-35mm/s的范围内可以控制闭合速度。5.驱动系统Schuler SMG高速试验冲压机的驱动系统是基于蓄能器技术的。氮气筒提供能量给活塞蓄能器，它再把油传输给导轨油缸。速度大小的控制装置是定位在活塞蓄能器和导轨油缸之间的。举例来说明一下，一个20000kN供油量的冲压机只需一个额定值为250KW的主驱动就可以了。蓄能器和进料泵的标准设计适合大概每分钟两个模拟冲程。而试验冲压机可以被设计为大约30000kN的最大冲压机供油量。6.效率使用液压高速冲压机来试验的目的为了提高生产能力，换句话说，也是减少花在成品冲压机试验上的时间。一台机械试验冲压机只能模拟根据滑动速度特性(驱动系统)和冲压缓冲系统设计的成品冲压机。尽管它结果的移植性好得多，但是它机器的成本比液压高速试验冲压机高得多。而且，液压高速试验冲压机能够通过不同的滑动特性来模拟不同铭牌和不同类型的冲压机的成型性能(液压或机械)(如图4)。对于一个侧板的普通的模具来说，在成品冲压机生产过程中需要的试验时间可能会达到6个星期。而经验表明，这试验时间可以通过使用上面描述的高速试验冲压机来使其缩短到80%。考虑到这些冲压机的各种各样的应用，这摊下来的时间就更短了，特别是当考虑到机械交叉压力或GT压力变化率高达每小时$3000的时候。7. 液压高速试验冲压机实例在图5中显示了Schuler SMG液压高速试验冲压机厂被设为美国汽车制造商。每台冲压机有18000kN的容量并配以可移动的压床垫板，可转动的导轨，四点控制的预加速模具缓冲装置，冲程限制和液压模具装夹系统。导轨运动曲线和导轨的速度，模具缓冲装置及其机械特性，这些就保证了机械大型纵横式冲压机的生产条件可以进行几乎一致的模拟。一个高精度的控制系统允许对可变的目标数据进行合适的输入，并对其相关参数，数据存储和数据传输的数字显示和图表显示进行直接监控。湘潭大学兴湘学院毕业设计任务书论文（设计）题目 铝型材挤压机液压部分的设计 学号 学生姓名 曾军凯 专业 机械设计制造及其自动化 指导教师姓名 系主任 一、主要内容及基本要求 1.介绍了挤压技术的相关知识及其对液压系统的相应要求，针对设计要求应用了新型节能泵源，并在此泵源基础上确定了整体滑阀回路。对部分主要回路进行了插装阀改进，同时，突破传统滑阀向等效插装阀的简单转换，将油路换向与元件运动分别控制，简化了系统。 2.阐述了理论基础，对溢流阀动态特性进行了计算机仿真，达到了多方面知识的综合训练。 3.对液压机构的几个部分都进行了基本的求解，液压缸机构形式的确定，挤压力的计算，液压缸尺寸的计算及其元件电机的选择。 二、 重点研究的问题 1.挤压机的结构分析 2.液压缸机构形式的确定 3.挤压力的计算 4.系统原理设计 5.元件及电机的选择 6.泵源及液压缸尺寸的计算 三、 进度安排各阶段完成的内容起止时间1 查阅资料、调研2012年3月上旬2 开题报告、制定设计方案2012年3月中旬3 设计2012年4月上旬4 分析、验证2012年4月中旬5 写出初稿2012年4月下旬6 修改，写出第二稿2012年5月上旬7 写出正式稿2012年5月中旬8 答辩2012年5月下旬四、 应收集的资料及主要参考文献【1】 上海煤矿机械研究所. 液压传动设计手册.【M】上海：人民出版社，1974.【2】 张利平. 液压气
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