Lightweight Design And Simulation Analysis Of Special Forging Robot Ar

Forging handling is one of the important processes in the forging production process.With the development of technology,some traditional forging production lines have been unable to meet the production needs of enterprises due to low production efficiency and poor safety.Therefore,it is necessary to introduce industrial robotic arms to improve the production efficiency of enterprises and automated production level.However,the manipulators designed according to traditional experience are often bulky and heavy in structure,which will not only increase the manufacturing cost,but also limit the improvement of the performance of the whole machine.Therefore,a lightweight design of the manipulator is required to reduce energy consumption,production costs and improve operating time.Based on this,this paper designs a lightweight special forging manipulator that can handle cylindrical forgings of different sizes,aiming at the handling of forgings in a forging production line of an enterprise.Based on the lightweight design of the structure,ADAMS simulation and finite element analysis were carried out on the manipulator;the structure of the manipulator arm was optimized with the lightest weight as the optimization goal;finally,the fatigue life of the bolt is predicted.The main research work and conclusions are as follows:(1)Determine the overall design plan and layout of the special forging manipulator based on the actual production needs of the enterprise,and determine the optimal configuration of the manipulator with reference to the existing manipulator structure and motion mechanism,and innovatively design the end effector to avoid the need for the design of the arm rotation action achieves the goal of the overall lightweight design of the robotic arm by removing a complete set of rotating devices.Based on the establishment of the manipulator model,the selection and calculation of the main power devices are carried out.(2)The kinematics simulation of the special forging manipulator was carried out by using ADAMS software,and the displacement,velocity and acceleration curves of key parts were obtained.The simulation results showed that the displacement curve had no inflection point,and the fluctuation range of velocity and acceleration was small,which verifies the movement of the manipulator and stability;dynamic simulation was also carried out,and the force of the main power device in one working cycle was obtained.The simulation results were compared with the calculation results,the maximum error was 4.8%,and the error was within the acceptable range.It was verified that the accuracy of the calculation results and the rationality of device selection.(3)The finite element analysis of the manipulator was carried out using ANSYS Workbench.From the analysis results,the maximum deformation of the manipulator was3.6mm,and the maximum equivalent stress was 43 MPa.The analysis results showed that the manipulator still has room for optimization.Taking the manipulator arm as the research object,taking the lightest mass as the optimization goal,the method based on response surface optimization is used to optimize the structure,the reduction of 274 kg to 204 kg,a reduction of about 25.5%,has achieved the goal of reducing the weight of the robotic arm.Aiming at the characteristics of the manipulator working under high temperature conditions,a thermal analysis was carried out,and the temperature distribution of the manipulator and the temperature field changing with time at higher temperatures were obtained.The analysis results show that all the mechanical structures of the manipulator are within rated operates at operating temperature.(4)The stress of the anchor bolts in one working cycle is obtained through theoretical calculation,and the finite element analysis is carried out according to the calculation results,and then the finite element analysis results are imported into the fatigue analysis software nCodeDesignLife to build the fatigue analysis process.Based on the linear fatigue cumulative damage theory,the fatigue life is predicted,and finally the working time of the anchor bolt with the shortest life is 12.7 years from the fatigue life cloud map,which is in line with the design expectations.