Key Components Design And Research Of Aluminum Profiles Automatic Stamping Line

Based on practical demands of a stamping firm,this paper aims to develop an automatic stamping system on the basis of original equipments.The key components of automatic stamping line are developed such as stamping manipulator and stamping die.The key components program are designed accroding to the contents of process,the stamping die structure are deviseded based on data of process parameters optimization,the manipulator key parameters are derived with optimizing synthetic model of the manipulator based on kinematic and dynamic indexes,and the manipulator typical path trajectory is designed based on modified trapezoidal velocity profile that is characterized by only two parameters which considered angular velocity and angular acceleration constraints.Finally,the manipulator physical model validation and model analysis are completed with dynamics simulation.Main research results of this paper:(1)The key components and workflow description of automatic stamping line are developed,the productivity is improved by more than twice compared to manual production.(2)By Deform simulation and experimental design,the significant factors(blanking clearance,punch step height,punch step width)are found effective on section quality.The prediction models are established with Response Surface Methodology(RMS),and three process parameters are derived with Genetic Algorithms(GA),the stamping die structure design is finished based on data of process parameters optimization.The results show that the modified models can predict section quality well;step-punching can significantly improve the clean-cutting rate,with little influence on die-roll rate and cutting work.(3)Kinematics models of manipulator based on initial configuration are established.Jacobian algebra features are used to evaluate kinematics performance,and several dynamics performance indexes based on rigid-body dynamics model-such as the inertia of links,the coupling of links and the limit of global driving torque are also defined as optimization functions.Selecting key parameters of mechanism as design variables and workspace and stiffness as constrains a standard multi-objective optimization problem can be formed,the parameters optimization is carried out with non-dominated sorting genetic algorithm(NSGA-II).The indexes of the manipulator such as isotropy,nonlinearity and torque limit have significantly improved.(4)A new smooth trajectory planning approach is proposed based on modified trapezoidal velocity profile that is characterized by only two parameters which considered angular velocity and angular acceleration constraints.The typical path of the manipulator trajectory is completed based on the method above.The trajectory planning results show that the planning algorithm can make full use of driving performances and shorten the manipulator operation time.(5)Statics analysis is carried out in Ansys Workbench(AWB).The rigid body dynamics and the coupled dynamics are also carried out in ADAMS and Ansys.Statics analysis shows that the displacement,stress and strain meet the requirements of the manipulator.Dynamics analysis results are consistent with the physical model established by the previous section,and through rigid flexible coupling dynamic analysis,the natural frequency of the manipulator is determined.