轻质复合构件车体便携式加工设备研制

【作者】 金浩；

【导师】 程寓；

【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】 随着科学技术的迅猛发展,新型特种车辆不仅需要优良的防护性能,也需要尽可能轻的车体重量,满足现代作战高机动性的要求。因此,需要努力进行装甲防护单元轻量化的研究。研究表明,工程陶瓷／玻璃钢轻质复合构件具有非常广阔的应用前景。但由于传统工艺的制约,在轻质复合构件车体成型过程中,无法准确预留一些装配特征,尤其是大量连接孔,需要根据装配现场的要求进行二次加工。因此,需要研制一种专用便携式加工设备来满足现场加工的需求。根据装配现场需求对便携式加工设备进行总体结构设计,综合考虑整机重量和结构刚度的影响,确定真空吸盘底座、支架、滑块和连接块等零部件的结构尺寸和材料,选择动力设备,研制样机。为了确保真空吸盘底座能够可靠吸附在工件上,需要对密封结构进行接触分析。利用Pro/E建立密封结构的三维几何模型,导入ANSYS中分析橡胶密封圈与工件的接触情况,重点讨论了橡胶硬度对接触的影响。考虑ANSYS Workbench在整机分析方面的优势,利用其对便携式加工设备进行整机模态分析,再利用模态测试仪器对整机进行模态试验,比较有限元仿真与试验测试的模态结果。结果表明电机工作频率与整机固有频率相差较大,不容易发生共振。因此,设备结构设计和电机选型合理,整机动态特性较好。为了验证所研制的便携式加工设备能够满足轻质复合构件的加工需求,需要用其进行加工试验。选择设备转速、定压进给压力和金刚石套料钻壁厚作为试验因素,进行三因素三水平的正交试验,分析各因素与加工时间的关系,得出最佳工艺参数,并通过方差分析,明确各因素对加工时间的影响程度。为了进一步提高孔加工质量,研制了预应力施加装置,并从加工试验和有限元分析两方面说明该装置使用效果明显。更多还原

【Abstract】 With the rapid development of science and technology, new special vehicles should not only have excellent protective performance, but also light body weight, in order to meet the requirements of high mobility of modern warfare. Therefore, it is necessary to do some research on reducing the weight of protective unit. Research shows that engineering ceramics/GFRP light composite structure has a very broad application prospect. Because of the constraints of traditional technology, some assembly features can not be accurately set aside in the process of body shaping, especially a large number of connective holes, which should be drilled according to the requirements of assembly. So a dedicated portable processing equipment should be developed to meet the processing needs.The overall structure design of the portable processing equipment should meet the requirements of assembly site. The structure dimensions and materials of some parts, such as suction cup base, support, slide and connective block, should be determined by considering the impact of total weight and structural stiffness. A prototype will be developed after selecting a motor.In order to ensure that the suction cup base can be adsorbed on the workpiece, contact analysis is needed to sealing structure.3D geometric model of sealing structure, which is created in Pro/E, is imported into ANSYS to analyze the contact performance between rubber seal and workpiece, especially discussing the impact of rubber hardness on the contact.Because of the advantage of machine analysis, ANSYS Workbench is used to analyze the machine modal of the portable processing equipment. And then, modal testing equipment is used to test the machine modal. Comparison is carried out between finite element analysis and testing results. The results show that the frequencies of the motor are very different from the machine natural frequencies, so it is not easy to set up resonance. Therefore, the structure design and motor selection of the portable processing equipment are reasonable. Dynamic characteristics of the equipment are good.In order to verify that the portable processing equipment can meet the processing needs of light composite structure, processing experiment is needed. Selecting speed, feed pressure and wall thickness of diamond trepanning drill as experimental factors, three factors and three level orthogonal experiment is carried out in order to analyze the relationship between factors and processing time and obtain optimal processing parameters. And then, analysis of variance (ANOVA) is used to show the significance of the factors. A pre-stressing equipment is developed to further improve the quality of drilling. The results of processing experiment and finite element analysis show that the pre-stressing equipment plays an important role on improving the quality of holes.更多还原