Load Analysis Of Key Structural Parts Of A High-speed Press Based On Virtual Prototyping

High-speed press is a kind of widespread used industrial forging machinery, currently thereliability of domestic high-speed presses is less than which overseas. In order to improve thedesign technique, it’s necessary to comprehensively acquire the loads of structural parts whe npresses working.The thesis relies on the National Science and Technology Major Project “Reliability growthtechnology of CNC high-speed stamping equipments” in2011. Based on the enclosedhigh-speed press J76-125E, the loads about connecting rod and crankshaft in drive system arefully analyzed though virtual prototyping and data statistics.Survey and tracking are conducted in a user company. The force and time scale of stress onthe upper-die when presses practical work are calculated theoretically. In real works, the pressloads make obvious distinction. The blanking force is far greater than forces in other time, but itsduration only occupy less than1%of whole using time whose most is no-load.In order to verify the virtual prototyping, piling experiment of press is done. The pressworks by different piling forces size and frequencies. The piling forces and slider accelerationsare measured and collected by tonnage meter and acceleration sensor.The virtual prototyping modeling of the press is conducted in Adams software, and verifiedby experimental data. The contrast of the data of piling forces and slider accelerations betweenexperiment and simulation proves the good agreement between virtual prototyping and realmachine on dynamic characteristic. So data from the simulation is credible. Referring to theexperiment30working conditions is set for multi-body dynamic simulation, and fully loads dataof aimed parts are obtainedSoftware of rain-flow counting method is coded, which is used for loads statistic. Besidesthe mean and amplitude, the thesis presents two other statistical variables: span and direction. Inthe rain-flow counting results, all of the four variables have stronger distribution regularities.In analysis about time histories and maximums of stress and strain of connecting rod andcrankshaft in different working conditions, the maximums of stress and strain are basically notaffected by piling frequency, but be affected by piling forces size mostly. And they make a linearcorrelation. Fatigue life contour plots of connecting rod and crankshaft could be reference.Potential danger zones of the two parts are pointed out. The fatigue lives of two structural partsmeet the designed requirements of the high-speed press in the full-load working condition, andbasically have no risk of material failure in the real working condition.