ZW32-12户外柱上真空断路器箱体成型的数值模拟

机械设计制造及其自动化论文，论文编号:JX1298 论文字数:25440.页数:58 附任务书，开题报告，文献综述,外文翻译

摘   要
 矩形盒件在拉深过程中材料的变形比较复杂,其变形规律以方形盒件为基础, 但又与方形盒件有区别。起皱和破裂是其拉深成形过程中的主要失效形式,而影响其成形质量的主要因素是压边力、材料机械性能、拉深模具参数、摩擦条件及板坯形状和厚度等。目前, 虽然已经对矩形盒件的成形在理论分析和实验研究方面做了大量的工作, 但因其变形的复杂性, 还不能像圆筒形件和方形盒件那样得出较为成熟的理论分析。随着有限元软件和计算机技术的不断发展, 在模具设计制造之前，可以运用有限元分析技术，模拟冲压过程，预测拉深过程中可能产生的起皱和破裂，及时修改冲压件的结构尺寸形状使之符合冲压件的冲压工艺条件。使得对矩形件成型规律的数值模拟成为可能。而有限元分析的前提是建立产品的三维SOLIDWORKS模型，并以Parasolid(*.x_t)格式保存导入有限元分析软件进行分析预测起皱和破裂可能性。
 本文以ZW32-12户外柱上真空断路器箱体为例，论述了凹模上打孔和毛坯上打孔工艺方法。从建立产品的三维SOLIDWORKS模型与有限元分析过程入手,分别对成形区域、安全区域、主应力等方面进行分析，分析结果表明存在应力集中区域，给出了发生起皱和破裂的成形极限图，表明了该断路器箱体的工艺设计存在缺陷，要多次完成拉深成形或更换拉深件材料等方法，以此分析结果，可作为模具设计制造的理论依据，同时可缩短真空断路器箱体产品开发周期，降低产品生产成本。

关键词：矩形盒件 SOLIDWORKS模型 有限元分析

Abstract
 In the process of rectangular box parts deep drawing shape, the material deformation is comparative complex.Its deformation law based on the square box parts, But with a square box parts of differentiated. Wrinkling and cracking are major invalidation in the deep drawing. And the major factor that affect on the quality of shape is the BHF, the mechanical properties of materials, drawing die parameters, friction conditions , slab shape ,thickness and so on. At the present time, although the rectangular box in the shape of the theoretical analysis and experimental research done a lot of work, but because of the complexity of the deformation, not as Cylindrical parts and as a square box parts that is more mature theory analysis. With the finite element software and computer technology continues to develop. before the die design production, making use of finite element analysis simulate the punching process, predict the wrinkling and cracking in the deep drawing process, modifies the structure size of the stamping to make it match the punching process condition of the stamping. Rectangular pieces of molding to make the numerical simulation of possible.But the premise of the finite element analysis is building up the 3D SOLIDWORKS model, and duct into the finite element analysis software by the Parasolid(*.x_t) format, then analysis and estimate the possibility of wrinkling and cracking.
 This text uses a chest of the ZW32-12 open air vacuseal breaker in the pillar for instance, discuss the technological proess of punching in the cavity die and the workhank.From the establishment of 3D CAD model and the process of finite element analysis, analysis respectively from forming zone, safety zone, major strain etc, the result enunciation existence strain concentration zone, given the breakdown occurred and wrinkle forming limit map, show that the circuit breaker box there are shortcomings in the design process, the need for a complete repeatedly drawing or replacement of drawing materials and so on. This analysis result, can be the theory basis of die design production, also can shorten the exploitation period of automobile panels, lower the cost of production.
 
Keywords：Rectangular box parts；Solidworks model；Finite element analysis
目  录
摘   要 I
Abstract II
第1章  绪  论 1
1.1  课题背景、目的、意义 1
1.2  国内外研究现状分析 1
1.3  本文主要研究的内容 3
第2章  矩形拉伸件毛坯的展开计算 4
2.1  矩形件拉深变形机理及分析 4
2.2  毛坯合理形状的简化作图方法 4
2.3 本章小结 7
第3章  三维造型的设计方法 8
3.1  三维造型方法 8
3.1.1 三维线框造型 8
3.1.2三维曲面造型 9
3.1.3 三维实体造型 10
3.2 SOLIDWORKS 11
3.2.1 SOLIDWORKS2008的特点 11
3.2.2 SOLIDWORKS的造型方法 12
3.3 本章小结 14
第4章  真空断路器箱体 15
4.1 真空断路器箱体起皱、开裂及缺角现象的分析 15
4.1.1 拉伸件加工工艺 16
4.2  拉伸件设计及制造时应注意的问题 18
4.2.1 零件底部转角部分易拉裂 18
4.2.2 零件口缘起皱 19
4.2.3零件表面粗糙度较差引起直边起皱 19
4.2.4压边圈 19
4.2.5判别拉伸次数并制定各工序毛坯尺寸 19
4.2.6 拉伸的热现象分析 20
4.2.7 零件成型后脱模苦难的原因及改进 21
4.3模具寿命分析 21
4.3.1 模具的失效分析 21
4.3.2 影响模具寿命的因素 22
4.3.3 改善措施 22
4.4 本章小结 23
第5章  有限元分析软件 25
5.1 ANSYS有限元分析软件 25
5.2 SolidWorks模型导入ANSYS的接口处理 27
5.2.1 SolidWorks文件的保存 27
5.2.2在ANSYS中导入SolidWorks模型 27
5.3 LS-DYNA 28
5.4 LS-PREPOST 29
5.5 有限元分析系统的发展现状及趋势 29
5.6 本章小结 31
第6章  设计内容 32
6.1真空断路器箱体工程图分析 32
6.2 绘制SOLIDWORKS三维图 32
6.2.1 绘制箱体产品图 32
6.2.2 绘制三维模型 32
6.3毛坯展开 40
6.4 有限元分析 40
6.5成形性能评价标准 42
6.6分析结果 43
6.7 本章小结 49
第七章  总  结 50
参考文献 51
致  谢 53

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