Project-Design And Lightweight-Research On High Speed Machining Center For Large Aluminum Components

Aluminum alloy bodywork gains its popularity for lightweight design in the field of high speed train, highway passenger vehicle and van. With the development of large complex thin-walled hollow profile extrusion technology and weld technology, large aluminum components have been extensive used. In recent years, the development of high-speed trains in China has made great achievements, but there are still has shortage in car body processing. The large equipment for processing still dependents in import. For lack of research of machine tools using in large aluminum components processing, domestic equipment only used for auxiliary process, which increasing the cost of car body processing and reduce the competitiveness of the domestic high-speed train in the world.On the basis of structural features and technological characteristics of large aluminum components, design the machining center by using the design method of traditional gantry-type machine tools for reference. To reduce the machine tools’weight, make the lightweight design to key parts.Based on the design requirements of machine center, use the modular design method and function analysis method to make overall design and realize milling, drilling, boring, expanding and reaming through clamping one time. In this chapter, introduced the separated columns and linear drive system as well.The static and dynamic characteristics analysis have been made to the original beam, and the key joint surface modeling has been established. Use virtual material model to simulate bolt joint surface of stand column, and got the elastic modulus, poisson ratio and density of virtual material. Use spring damper unit model to simulate guide joint surface, and got the stiffness coefficient of spring. By the finite element model with surface parameters, analysis displacement deformation of the cutting tools in condition of gravity and cutting force. Analyze the he first six order of natural frequency.Improve the beam based on topological optimization method to realize lightweight. Established the finite elements model of beam in Hypermesh Software, and set the optimization object, constraint and boundary conditions. Use the topology optimization model of maximum stiffness and structural dynamic topology optimization model of characteristic value to improve the stiffness and inherent frequency. By this method, reduced the weight of the beam as well.This topic is funded by2012Shandong Province Science and Technology Development Plan (item number:2012GGE27113).