Simulation Analysis And Optimization For The Clmping Mechanism Of The Large Die-casting Equipment

With the development of the computer technology, many developed countries, such as theJapan, the Europe countries and the United States, have commonly used the finite elementanalysis and the virtual prototyping technology in the development of the die-casting machine.Their machines have obvious advantages in terms of performance, stability, reliability andcomfort, but the domestic technology development is also in the blank with great gap with theinternational standards. We should change the traditional design method which was mainlybased on experience design and uniform variety design in the development of the die-castingmachine. Instead, we must adopt new method which could meet many varieties, small batch,high quality, short cycle and low cost, so the CAE (Computer Aided Engineering) technologywas an essential part of this new method. The CAE technology could significantly improvethe scientific nature of the product design to reduce the blindness and improve designefficiency. It was mainly used to predict and estimate the strength, the life and theperformance of the products. The clamping mechanism is the key part of the die-castingmachine. Its reliability and stability directly influence the quality of the castings and theperformance of the die-casting machine. The paper researched and analyzed the clampingmechanism of the DM2005die-casting machine in many aspects based on the virtualprototyping technology. The main contents were as follows:（1）By using the three-dimensional modeling software Pro/ENGINEER, we couldestablish the die-casting machine model based on the provided CAD drawings. Thereby wecould establish the virtual prototype model of the die casting machine.（2）Carrying out a detailed analysis of the kinematic and mechanical properties of theclamping mechanism, the paper provided a theoretical basis for the dynamic simulation andoptimization design of the clamping mechanism.（3）By the multi-body dynamics simulation analysis of the clamping mechanism usingthe ADAMS, we could master the movements and mechanical properties of the everycomponent. And then we could carry out the multi-flexible body dynamics simulationanalysis of the clamping mechanism in order to better meet the actual situation. By doingthese things, the paper provide an idea and a little experience in multi-flexible body dynamicssimulation analysis. And also provide basic data for the finite element analysis and fatigue lifeevaluation.（4）By using the ADAMS/Vibration module in replace of the finite element software, the paper used a new method which was more reasonable and effective to carry out the modalanalysis of the whole flexible body to understand the dynamic characteristics of the clampingmechanism. And also provide basis for harmonic response analysis and dynamicsoptimization.（5）The paper optimized the clamping mechanism to increase the expansion forcecoefficient, which the clamping mechanism could achieve a greater clamping force under thedriving force, in order to improve the overall performance of the die-casting machine.The paper discusses the dynamics simulation and analysis of the die casting machine andthe speed, acceleration, mechanical properties of the key components has obtained. The resulthas shown that the dynamic strength and fatigue life of the die-casting machine cancompletely meet the design requirements; the modal analysis of the clamping mechanismproved that the fixed-interface modal synthesis method is very efficiency. The first20naturalfrequencies and mode shapes provide basis to reduce vibration and noise; the clampingmechanism has been optimized, and the expansion coefficient raises to23.59, which is closeto the international advanced level (usually about26). So the work efficiency andenergy-saving level have been increased to improve the whole quality of the die castingmachine.