CN116663375B - Ram structure optimization method based on finite element analysis - Google Patents
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Abstract
The application discloses a ram structure optimization method based on finite element analysis, which comprises the following steps: establishing a three-dimensional model of a solid ram structure without a rib cavity as an initial model, and determining the material properties of the initial model; performing finite element analysis on the initial model to obtain static deformation and 1-order modal frequency; performing topological optimization on the initial model to obtain an optimized material layout form and an optimized model; carrying out parameterized modeling on the optimization model based on static deformation and 1-order modal frequency, and determining characteristic parameters; carrying out correlation analysis on the characteristic parameters; and carrying out size optimization analysis on the optimization model to obtain an optimal solution of the size of the characteristic parameters, and obtaining the parameter optimization model. According to the invention, through topological optimization and size optimization analysis, the mass of the ram structure can be reduced while the static stiffness and modal frequency are satisfied, the weight is reduced, the dynamic and static performances of the whole machine tool are improved, and a reasonable method for optimizing the design of the ram structure is provided theoretically.
Description
Technical Field
The invention relates to the technical field of machine tool structure analysis and optimization, in particular to a ram structure optimization method based on finite element analysis.
Background
The high-end five-axis processing machine tool in the aerospace field mainly processes important parts such as airplanes, spacecrafts and the like which adopt materials such as large titanium alloy, composite materials and aluminum alloy, and the parts are large in size, high in removal rate and complex in molded surface, so that the precision requirement on the five-axis processing machine tool is very high, and once deviation occurs, the parts are damaged, and the damage which is difficult to estimate is caused.
For a high-end five-axis machining center, the ram belongs to an important moving part, and has the functions of supporting the A/C swing head connected with the front end of the ram, realizing the movement of a machine tool along the Z direction in the cutting movement process, and directly influencing the precision and efficiency of machined parts by the quality of the ram, so that the reasonable form of the ram structure needs to be studied in an important way, the requirements on rigidity and stability are met, the weight is reduced, and the dynamic characteristics of the machine tool are improved. However, at present, an empirical design or a comparison is mainly adopted for a ram structure, an optimal solution mode is selected, the repeated design process is increased by the mode, the design period is further increased, and meanwhile, the influence of the characteristic dimension on the structure, such as the thickness of the outer wall and the thickness of the rib cavity, is not studied in detail, so that structural materials are not distributed reasonably, and deviation exists in rigidity and stability, and the manufacturing cost of the structure is improved.
Therefore, there is a need to develop a ram structure optimization method based on finite element analysis.
The information disclosed in the background section of the invention is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
Disclosure of Invention
The invention provides a ram structure optimization method based on finite element analysis, which can lead the ram structure to reduce the mass while meeting the static deformation and 1-order modal frequency through topology optimization and size optimization analysis, realize light weight and improve the dynamic and static performances of the whole machine tool, and theoretically provide a reasonable method for the optimization design of the ram structure.
The embodiment of the disclosure provides a ram structure optimization method based on finite element analysis, which comprises the following steps:
establishing a three-dimensional model of a solid ram structure without a rib cavity as an initial model, and determining the material properties of the initial model;
performing finite element analysis on the initial model to obtain static deformation and 1-order modal frequency;
performing topological optimization on the initial model to obtain an optimized material layout form, and obtaining an optimized model;
performing parameterized modeling on the optimization model based on the static deformation and the 1-order modal frequency, and determining characteristic parameters;
carrying out correlation analysis on the characteristic parameters;
and carrying out size optimization analysis on the optimization model to obtain an optimal solution of the size of the characteristic parameter, and obtaining a parameter optimization model.
Preferably, the finite element analysis includes a static analysis and a modal analysis.
Preferably, the static analysis includes three states, namely a gravity-only state, a state under the action of gravity and the AC pendulum, and a state under the action of gravity, the action of the AC pendulum, and the action of cutting force.
Preferably, the topology optimization comprises:
and respectively carrying out topological optimization on the ram structure in a static deformation minimization and 1-order modal frequency maximization mode to obtain a structure retaining and removing area.
Preferably, the characteristic parameters comprise the thickness of the left, right, upper and lower outer walls and the thickness of the rib plate.
Preferably, the correlation analysis comprises:
and determining the static deformation and the 1-order modal frequency by taking the characteristic parameters as an optimization object, performing correlation analysis on the characteristic parameters, and determining the influence degree of the characteristic parameters on the static deformation and the 1-order modal frequency.
Preferably, the size-optimized analysis comprises:
and setting an initial value and a value range of the dimension, and analyzing by taking the static deformation and the 1 st-order modal frequency as targets.
Preferably, setting an initial value and a range of values of the dimension, and performing analysis targeting the static deformation and the 1 st-order modal frequency includes:
determining the sizes of a plurality of groups of characteristic parameters, carrying out finite element analysis on each group of characteristic parameters to obtain corresponding static deformation and 1-order modal frequency, and respectively calculating the difference value between the static deformation and the 1-order modal frequency corresponding to the initial model, wherein the characteristic parameter with the smallest difference value is the optimal solution.
Preferably, the method further comprises:
and perfecting the parameter optimization model according to the process and the requirements related to the ram structure to obtain the final ram structure.
The beneficial effects are that:
the method has the advantages that the optimization analysis is carried out on the ram structure from two aspects of topological optimization and size optimization by utilizing finite element analysis software, and the characteristic parameters which have obvious influence on the performance of the ram structure are determined through correlation analysis, so that the direction of optimal design can be provided more accurately, the materials of the structure are distributed reasonably, the structural performance is ensured, the light weight is realized, and meanwhile, the technical support is provided for the improvement of the dynamic characteristics of the whole machine.
The method and apparatus of the present invention have other features and advantages which will be apparent from or are set forth in detail in the accompanying drawings and the following detailed description, which are incorporated herein, and which together serve to explain certain principles of the present invention.
Drawings
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts throughout the exemplary embodiments of the invention.
FIG. 1 shows a flow chart of the steps of a ram structure optimization method based on finite element analysis, according to one embodiment of the invention.
Fig. 2 shows a schematic view of a solid structure of a ram without a rib cavity according to one embodiment of the invention.
Fig. 3 shows a schematic representation of a topology optimized layout based on minimal static deformation according to an embodiment of the invention.
FIG. 4 shows a schematic diagram of a topology optimized layout based on 1 st order modal frequencies according to one embodiment of the invention.
Fig. 5 shows a schematic diagram of a ram structure of a parameterized feature according to one embodiment of the invention.
FIG. 6 shows a schematic diagram of correlation analysis of parameterized features according to one embodiment of the invention.
Detailed Description
Preferred embodiments of the present invention will be described in more detail below. While the preferred embodiments of the present invention are described below, it should be understood that the present invention may be embodied in various forms and should not be limited to the embodiments set forth herein.
In order to facilitate understanding of the solution and the effects of the embodiments of the present invention, a specific application example is given below. It will be understood by those of ordinary skill in the art that the examples are for ease of understanding only and that any particular details thereof are not intended to limit the present invention in any way.
Examples
FIG. 1 shows a flow chart of the steps of a ram structure optimization method based on finite element analysis, according to one embodiment of the invention.
As shown in fig. 1, the ram structure optimization method based on finite element analysis includes: step 101, establishing a three-dimensional model of a solid ram structure without a rib cavity as an initial model, and determining the material properties of the initial model; 102, carrying out finite element analysis on an initial model to obtain static deformation and 1-order modal frequency; step 103, performing topological optimization on the initial model to obtain an optimized material layout form and an optimized model; 104, carrying out parameterized modeling on the optimization model based on static deformation and 1-order modal frequency, and determining characteristic parameters; step 105, carrying out correlation analysis on the characteristic parameters; and 106, performing size optimization analysis on the optimization model to obtain an optimal solution of the size of the characteristic parameters, and obtaining a parameter optimization model.
In one example, the finite element analysis includes static analysis and modal analysis.
In one example, the static analysis includes three states, a gravity-only state, a state under the force of gravity and AC pendulum, and a state under the force of gravity, AC pendulum, and cutting force, respectively.
In one example, the topology optimization includes:
and respectively carrying out topological optimization on the ram structure in a static deformation minimization and 1-order modal frequency maximization mode to obtain a structure retaining and removing area.
In one example, the characteristic parameters include the thickness of the left, right, upper, and lower outer walls and the web thickness.
In one example, the correlation analysis includes:
and determining the static deformation and the 1-order modal frequency by taking the characteristic parameters as an optimization object, performing correlation analysis on the characteristic parameters, and determining the influence degree of the characteristic parameters on the static deformation and the 1-order modal frequency.
In one example, the size optimization analysis includes:
and setting an initial value and a value range of the dimension, and analyzing by taking static deformation and 1-order modal frequency as targets.
In one example, setting the initial value and the range of values for the dimension, and targeting the static deformation and the 1 st order modal frequencies for analysis includes:
determining the sizes of multiple groups of characteristic parameters, carrying out finite element analysis on each group of characteristic parameters to obtain corresponding static deformation and 1-order modal frequency, and respectively calculating the difference value between the static deformation and the 1-order modal frequency corresponding to the initial model, wherein the characteristic parameter with the smallest difference value is the optimal solution.
In one example, further comprising:
and perfecting the parameter optimization model according to the process and the requirements related to the ram structure to obtain the final ram structure.
Fig. 2 shows a schematic view of a solid structure of a ram without a rib cavity according to one embodiment of the invention.
Specifically, as shown in fig. 2, a three-dimensional model of a ram structure with a Solid non-open rib cavity is firstly established, wherein the positions connected with the a/C swing heads and the parts contacted with the sliding blocks are required to be reserved, the other parts are drawn to be Solid, the Solid parts are led into Ansys Workbench software, the type of a set unit is Solid187, and the material is set to be 16Mn.
And carrying out finite element analysis on the ram structure, wherein the static analysis comprises static analysis and modal analysis, the static analysis comprises that the ram is only in a gravity state, the ram is subjected to gravity, the acting force of an AC swing head and the acting force of the gravity, the AC swing head and the cutting force, the static deformation result and the front 3-order modal frequency result of the ram in three states are respectively obtained, then the result is taken as a reference, and the closer the static deformation and the 1-order modal frequency of the optimized structure are to the result, the better the structure optimizing effect is.
Fig. 3 shows a schematic representation of a topology optimized layout based on minimal static deformation according to an embodiment of the invention.
FIG. 4 shows a schematic diagram of a topology optimized layout based on 1 st order modal frequencies according to one embodiment of the invention.
3-4, performing topological optimization on the ram structure from two angles of statics and modes in Ansys Workbench, wherein from the statics angle, the main optimization target is minimum static deformation, determining a critical area and an optimizable area which need to be reserved according to load and boundary conditions set by static analysis, and setting the proportion of mass to the structure after optimization before optimization; from the mode angle, the main optimization target is the maximum 1-order mode frequency, the initial reserved and optimized area is determined according to the boundary condition, the mass ratio is set the same as the minimum static deformation, and the optimized area which is reserved and removed finally is obtained through software iterative optimization, so that the optimization model is obtained.
According to the optimized model, an initial three-dimensional model of the ram structure after topological optimization is obtained by combining actual casting and processing conditions, and static force and modal analysis is carried out to obtain deformation and modal frequency results of the initial three-dimensional model.
Fig. 5 shows a schematic diagram of a ram structure of a parameterized feature according to one embodiment of the invention.
As shown in fig. 5, the dimensions of the main features, including the thickness of the outer wall and the thickness of the tendon cavity, are parameterized, initial feature values are established, then a model is imported into the Ansys Workbench software to add materials and unit types, the four features are selected in the design model to complete parameterized initial selection, and meanwhile, static deformation and 1-order modal frequency selection in the Mechanical are completed to complete selection of target parameters.
FIG. 6 shows a schematic diagram of correlation analysis of parameterized features according to one embodiment of the invention.
As shown in fig. 6, the correlation analysis is performed on the characteristic parameters, four wall thicknesses, an initial value of the thickness of the rib plate and a value range assigned to each parameter are set in a Parameters Correlation module in Ansys Workbench, wherein the initial value of the outer wall is 50mm, the value range is 45mm-55mm, the initial value of the thickness of the rib plate is 20mm, the value range is 15mm-25mm, and the optimization targets are static deformation size (mm) and modal frequency value (Hz). The correlation bar graph of the characteristic parameters is obtained through software analysis, the influence of the thickness of the outer wall on the lower side of the ram structure on static deformation and 1-order modal frequency is the greatest, and the thickness of the rib plate has a certain influence on the modal frequency, because in the correlation analysis, the closer the bar graph is to +/-1, the higher the correlation of the parameter on the target parameter is, the more the bar graph of the thickness of the outer wall on the lower side of the static deformation or 1-order modal frequency is close to +/-1, the other three wall thicknesses are almost close to 0, and the correlation coefficient of the thickness of the rib plate exceeds 0.5 when the modal frequency is taken as an optimization target, so that the modal frequency of the ram structure can be improved to a certain extent by optimizing the parameter, and the influence degree of the thickness of the outer wall on the structure is not great, so that the influence degree of the parameter on the structure can be obtained by the correlation analysis.
And (3) carrying out size optimization analysis on the ram structure, setting an upper limit value and a lower limit value of the size parameter completed in the step (six) in a Response Surface Optimization module, and finally obtaining the optimized characteristic size value, as shown in a table 1.
TABLE 1
Perfecting according to the process and hoisting requirements related to the ram structure, such as adding hoisting holes, connecting holes, process holes and the like, and finally forming the optimized complete ram structure.
In summary, the method can effectively perform optimization design based on static deformation and 1-order modal frequency on the solid ram structure without the rib cavity, comprises topology optimization and size optimization for determining material distribution, and can analyze the characteristic parameters with great influence on the structure, so that the direction of the optimization design can be provided more accurately, the structural performance is ensured, the structure is light, and the dynamic performance of the machine tool is improved.
It will be appreciated by persons skilled in the art that the above description of embodiments of the invention has been given for the purpose of illustrating the benefits of embodiments of the invention only and is not intended to limit embodiments of the invention to any examples given.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the various embodiments described.
Claims (4)
1. The ram structure optimization method based on finite element analysis is characterized by comprising the following steps of:
establishing a three-dimensional model of a solid ram structure without a rib cavity as an initial model, and determining the material properties of the initial model;
performing finite element analysis on the initial model to obtain static deformation and 1-order modal frequency;
performing topological optimization on the initial model to obtain an optimized material layout form, and obtaining an optimized model, wherein the topological optimization comprises the following steps: respectively carrying out topological optimization on the ram structure in a static deformation minimization and 1-order modal frequency maximization mode to obtain a structure retaining and removing area;
carrying out parameterized modeling on the optimization model based on the static deformation and the 1-order modal frequency, and determining characteristic parameters, wherein the characteristic parameters comprise thicknesses of left, right, upper and lower outer walls and rib plate thicknesses;
and performing correlation analysis on the characteristic parameters, wherein the correlation analysis comprises the following steps: taking the characteristic parameters as an optimization object, determining the static deformation and the 1-order modal frequency as an optimization object, carrying out correlation analysis on the characteristic parameters, and determining the influence degree of the characteristic parameters on the static deformation and the 1-order modal frequency;
performing size optimization analysis on the optimization model to obtain an optimal solution of the size of the characteristic parameter, and obtaining a parameter optimization model, wherein the size optimization analysis comprises: setting an initial value and a value range of the dimension, and analyzing by taking the static deformation and the 1-order modal frequency as targets, wherein the method comprises the following steps:
determining the sizes of a plurality of groups of characteristic parameters, carrying out finite element analysis on each group of characteristic parameters to obtain corresponding static deformation and 1-order modal frequency, and respectively calculating the difference value between the static deformation and the 1-order modal frequency corresponding to the initial model, wherein the characteristic parameter with the smallest difference value is the optimal solution.
2. The finite element analysis-based ram structure optimization method of claim 1, wherein the finite element analysis comprises a static analysis and a modal analysis.
3. The finite element analysis-based ram structure optimization method of claim 2, wherein the static analysis comprises three states, namely a gravity-only state, a state under the action of gravity and AC swing, and a state under the action of gravity, AC swing and cutting force.
4. The finite element analysis-based ram structure optimization method according to any one of claims 1 to 3, further comprising:
and perfecting the parameter optimization model according to the process and the requirements related to the ram structure to obtain the final ram structure.
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