Design Of A Tubular Parts Forming Machine

The manufacturing industry in China is in the stage of transition from traditional to modern. Automation, integration, intelligence have become the development trend of manufacturing. Tubular parts are used widely in the field of vehicle engineering. But traditional forming techniques which are inefficient, high cost, high energy consumption are still used in many Chinese companies for manufacturing of tubular parts. Technical transformation is imperative. This thesis concerned the design of a tubular component forming machine which is commissioned by Xia Men Gesin Metal Manufacturing Co., Ltd.The new machine aimed at realizing low cost and high automation. The design of new machine includes four parts: mechanical structure design, finite element analysis of bending of a tube, die design, hydraulic system. As follows:1. In the first part of the thesis, the design idea and requirement of the machine were determined at first. Then the basic scheme and technical route were designed. Then the component structure and assembly structure were designed with CREO and AutoCAD. The machine is composed of guide parts, worktable, frame and hopper. Working process of the machine as following steps: Tube billets move from hopper into guide parts. Then they move into worktable which is equipped with bending die and punching die. After that they will be bended and punched. Finally, finished parts will drop to the guide plates.2. The bending process of tubes is simulated with the finite element software Dynaform.Simulation results were analyzed and studied. Through the simulation of the bending process of the metallic tube, forming data of metallic tube with different material, thickness and relative bending radius are obtained. These data provide guidance for components, die and machine design.3. In the die design part, the process of bending and punching were analyzed at first.Based on the results of finite element analysis above, the die clearance, working dimensions and forming force are designed and determined. After the die were virtually assembled and operated on Creo, the sizes of the die were determined.4. The design scheme of hydraulic system is determined at first. Second, the working conditions, task-requirement and load characteristic of hydraulic system are analyzed. Then the hydraulic schematic diagram was designed. According to the working load, hydraulic cylinders and other components of the hydraulic system are calculated and selected.