Structural Analysis And Optimization Of Rolling Head Of Disk Forming Machine

As an advanced continuous local plastic rotary forming process,the rolling forming of disc-shaped parts is of great significance to shorten the production cycle of disc-shaped parts,reduce production costs,and improve the overall performance of the disc-shaped parts.It also has significant technical and economic advantages such as low forming load,automated production process,and near net forming.Therefore,research and development of disc rolling forming equipment can solve the problem of equipment capacity for large-scale turbine disc manufacturing in China,meet the needs of large-diameter turbine discs in aviation,military and energy industries,promote the development of these industries,and get rid of domestic demand for foreign imports.The disc rolling forming experimental machine that has been developed in China is the first generation prototype.The equipment has poor rigidity and weak loading capacity,which cannot meet the rolling forming of medium and large-sized discs.The new disc rolling forming machine to be developed is the second generation product.It has a greater improvement in structural rigidity and loading capacity than the first generation prototype,and the structure of the equipment is also different from the first generation prototype.The cantilever structure and large forming load make the rolling head unit one of the main design difficulties of the disc rolling forming machine.In addition,the size of the forming load is closely related to the size of the rolling head and the structural form,and the size of the forming load is one of the most important reference indicators for designing the disc rolling forming machineIn this paper,the rolling head and the rolling head unit of the second-generation disc rolling forming equipment are taken as the research object,and the finite element software is used to analyze the assembly of the rolling head and the rolling head unit,the structure was improved based on the results of the finite element analysis.The influence and restriction of each structural element of the integral rolling head on the rolling forming process and rolling equipment are analyzed.At the same time,referring to the technical specifications of the equipment,a design scheme for the rolling head was initially determined.Then according to the initial design of the roller head,the forming load of the roller head is calculated through the calculation program.Based on software,according to the initial design of the roller head and its forming load,the equivalent stress field distribution and deformation of the roller head are analyzed.The analysis results show that the stress of the initial plan rolling head meets the requirements,but the amount of deformation is too large,the overall maximum deformation is greater than 0.5 mm,which does not meet the requirements.Based on the above results,according to the structural characteristics of the rolling head,three more improved rolling head design schemes are proposed,and the load calculation and finite element analysis are continued to study the stress and deformation of different rolling heads,to evaluate the feasibility of the schemes and screen them.The analysis results show that both scheme 2 and scheme 3 meet the requirements,and the deformation between the two is almost the same.Combining the factors of actual design and installation to avoid interference,scheme 3 is more suitable.The finite element analysis is carried out based on the two proposed structural schemes of the roller head unit.According to the assembly model of the roller head unit,combined with the working conditions,the contact relationship and boundary conditions between the main components of the roller head unit are analyzed.Based on software,the equivalent stress distribution and deformation of the assembly of the roller head unit are analyzed,and the structural rigidity and local strength of the roller head unit are checked.The analysis results show that the stiffness of the two types of rolling head units meet the requirements;most of the stresses of the two types of rolling head units are below 60MPa,and the maximum equivalent stress of each component is less than the yield limit,which meets the strength requirements.A comparison of the results of the two structural analyses reveals that the amount of deformation of the two schemes is not much different,either overall or on the main parts.Combined with the difficulty of changing the inclination angle,the structure of scheme one is considered more suitable.According to the selected roller head unit assembly model,modal analysis is carried out on the roller head unit assembly,which provides a basis for structural design optimization.