Structural Design And FEM Anaslysis Of A Rotary Forging Machine

Rotary forging is a kind of special forming process which applys local loading and accumulative deformation to the workpiece to achieve the integral forming. Rotary forging machine is a kind of special forming equipment for rotary forging. There are many defects exist in traditional designing method, such as long periods,structural redundancy,high cost and lack of the validation etc. If the machine is designed using the normal calculation methods, the exact results can not be get and the stress and the strain state can not be known. As a result, the weight of the part is increased, which usually waste material and can not improve the quality of the design. With the popularization and application of CAD/CAM/CAE, the technology of Finite Element Analysis has been widely studied and applied by project designers, and now has gained good economical benefits. The technology of Finite Element Analysis has been widely used in aviation, navigation, architecture and mechanism but not in Forging press machine, so most of this kind products are designed by traditional methods. The paper analyzed the frame of the rotary forging machine and make some improvements on the structure of the upper and the lower bridge so that stress distributions of the upper and lower bridge are more equable and reasonable. We obtained the following obvious results: decrease the weight of the machine, improving the strength and stiffness, and provided the academic law for the structural design and mend.Firstly the working principles,structural features,designing methods,the status of the research and the application on the rotary forging machine home and overseas are introduced, then the theories of the finite element analysis and the functions of the ANSYS software are introduced. Then the analysis are carried on the characteristic of the concerned parts, such as slider,oil cylinder,frame and the transmission system and the formulas of calculating the strength of the machine are given. Last, the finite model of the 4000KN rotary forging machine is build up to carry on the analysis, the distribution laws of the stress,strain and the displacements of the frame are obtained. On the basis of the features of the stress and the strain, the structure of the upper bridge and the lower bridge of the 4000KN rotary forging machine are modified and the thickness of the low-stress steel plates are adjusted. After that, the stress distributions are more reasonable, the maximum stress value of the upper bridge changes from 157MPa to 150MPa, decrease by 4.5ï¼…, and the weight decrease by 12.8ï¼…, the maximum value of the lower bridge changes from 183MPa to 164MPa, decrease by 10.4ï¼…, and the weight decrease by 10.8ï¼….