Design And Research On Motor Joint Sleeve Forming Machine

Motor joint sleeve is a kind of approximate rectangular small sheet metal parts, mainly used for the motor winding connection and fixation. Because motor joint sleeve is not the standard part and it has different sizes and shapes, the current motor joint sleeve processing is operated mainly by a manual way. Only some of the enterprises developed motor joint sleeve forming machine, but it usually has the disadvantage of single processing type and low accuracy. As the demand for motor joint sleeve and its forming accuracy has improved in the motor industry, designing and developing a wide applicable range, high efficiency and joint sleeve forming machine with high forming precision have become the urgent needs for the development of motor industry. To achieve this goal, this paper carried out the unfold size calculation, bending force deduction and experimentation, springback numerical simulation and experiment research. The main work is as follows:(1) Because the present unfold size calculation method is not considered material properties, the results of the calculation have some error. The author determined the accurate method for calculating motor joint sleeve unfold size, and the migration coefficient table of H62 brass which is commonly used in producing motor joint sleeve has been obtained by experiment. Moreover, solving bending force model was established. Then through the results, the author analyzed the factors influencing the bending force. At last, the author acquired the bending force of H62’s U-shape forming through experiments.(2) The author analyzed the modeling and calculation method of numerical simulation of springback problem, and the author determined to use the method by ABAQUS software to present the dynamic explicit module of the forming process and static implicit module to of the springback process. For motor joint sleeve forming process, the finite element model of springback simulation is established, and through the tensile test, the mechanical properties of simulation object H62 brass have been acquired.(3) The author analyzed the main process parameters which affect the springback of motor joint sleeve. Through the method of combining orthogonal test and software, the author got the primary and secondary order of influencing factors as well as the optimal forming process parameters. Then he designed mould and carried on forming experiment which verified the validity of the ABAQUS simulation results. Finally, the mould compensation method is adopted, and the die structure is optimized again in order to reduce the springback further.(4) According to the production requirements, combined with previous theoretical analysis, numerical simulation and experiment, the author confirmed the sequential control scheme of the motor joint sleeve forming machine, and completed the design of the whole machine, including the mechanical structure and hydraulic system. Finally the author carried on the 3D model and simulation analysis by using NX8.0 software, which validated the rationality of the design.