Research On Low Carbon And Energy Saving Optimization Method For Stamping Forming Process

Stamping plays a major role in sheet metal forming process,and stamping industry is the basic industry in mechanical manufacturing.In stamping processes,large demanded load,high energy consumption and energy waste,unstable forming quality have become the key influential factors in improving the energy efficiency and decreasing the production cost.How to reduce the energy consumption and improve the energy efficiency of stamping industry have become one of the considerable issues in low carbon manufacturing.With the support of National Natural Science Foundation of China and International Cooperation and Exchange of the National Natural Science Foundation of China,this dissertation focuses on energy consumption analysis and quantification of stamping processes,and the low carbon optimization for stamping processes and sheet metal forming equipment,the main research contents show as follow:(1)An energy consumption quantification method for sheet metal forming process is proposed.On the basis of the plastic deformation theory of sheet metal stamping,the blank was divided into specific subparts to investigate their energy consumption features according to the deformation characteristics of stamping parts.The energy consumption models for typical products of cold and hot stamping process were established,and the identification method of key process parameters on energy consumption of stamping process were proposed.(2)A low carbon evaluation mechanism with multi targets for sheet metal forming process was established with considering low carbon forming evaluation indices synthetically,which are forming quality and forming energy consumption.In order to reduce the energy consumption of forming under the condition of meeting the forming quality,low carbon optimization for stamping process was proposed.Orthogonal experimental design and Latin hypercube method were used to sample the data points.The corresponding energy consumption of forming and forming quality of each sample were quantified.Response surface method was used to establish the multi-objective optimization model.The optimized process parameters were obtained by multi-objective optimization algorithm.Furthermore,the application was conducted on typical products of cold and hot stamping process,and the optimized process parameters are used to carry out the deep drawing experiments and verification,the result shows that the forming quality is obviously good with lower energy consumption.(3)The energy consumption of slide-guiding system in stamping process is quantified.In the permiting of guaranteeing the forming quality and accuracy of stamping process,and under the constraint condition of forming quality and load demand,the slide guide system is optimized with the goal of minimum energy loss.The proposed method is applied to rapid sheet metal drawing hydraulic press for construction machinery,which could provide an excellent reference for the structure optimization and redesign of slide guide system of hydraulic presses.(4)Based on the carbon footprint models in stamping process,the energy consumption features of stamping equipment was analyzed,the energy performance of stamping forming equipment under the optimal parameters was identified and quantified.In order to reduce the energy consumption of forming equipment in stamping process,the energy-saving control method of forming equipment by using energy matching method was proposed.The energy saving method of forming equipment was applied to a stamping process chain,the carbon emission was further restrained and reduced in stamping process from the perspective of equipment controlling.