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Fine blanking press frame is one of the core components of the fine blanking press. Good performance of the frame is of great importance to ensure blanking precision. Simultaneously, lightweight of the frame would decrease the total press weight, and reduce the consumption of manufacturing and transportation. In this paper, the topology optimizatio...
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Citations
... Guillen et al. [16] developed a framework for the topological optimisation of finned heat exchangers that combines fluid dynamic optimisation programmes to reduce the drop in pressure in the heat exchanger during operation. Lin [17] applied topological optimisation methods to facilitate the design of nonmanufacturable design features and ensure their reliability. Duan [18] used SIMP methods to conduct topological optimisation on a high-speed hydraulic press, achieving a structure with better quality and higher stiffness. ...
... Because of the large size of the press frame, the reinforcement structure is mostly welded or bolted. Since these details have little influence on the overall strength and stiffness of the frame, they were ignored in the modelling of the real frame [17]. We smoothed the small round holes, filler holes, rounded corners, and chamfers, which do not have a significant influence on the structural performance; unnecessary raised parts, such as welds and small edge parts, were removed; threaded holes, rivet holes, oil holes, etc., were deleted. ...
This article aims to optimise the structure of a press machine to enhance its stability and accuracy, as well as reduce the frame deformation during processing. The outer supporting frame of the JH31-250 press machine (Zhejiang Weili Forging Machinery Co., Ltd, Shaoxing, China) is used as a typical sample for exploring optimisation. Commercial software is utilised to conduct a finite element analysis on the three-dimensional model of the press machine frame. A topological optimisation algorithm using the solid isotropic microstructures with penalisation (SIMP) method is then applied to improve the structure of the press frame. The size of the topological structure is further refined with the response surface method and particle swarm optimisation method to ensure it is more relevant to engineering application. The analysis results indicate that the initial frame’s deformation under the static conditions is 0.4229 mm, and after optimisation, the deformed structural displacement is 0.2548 mm, a decrease of 39.75%. Additionally, a simplified experimental method is designed to effectively validate the simulation and the proposed design.
... Inaccuracies are caused in particular by elasticities in the drive train [1], clearance in bearings [2], a lack of dynamical stiffness at high stroke speeds [3] and offcenter loading of the ram [4][5][6]. To counteract these effects, the topologies of presses have been optimized in recent years with regard to maximum static (no motion) [7,8] and dynamical [9] stiffness (in motion). Designing for maximum stiffness involves considerable modeling and material effort. ...
... The overall weight was reduced by 30.85%, and the maximum equivalent force was reduced by 19.98%, which achieved the design goals of structural optimization and lightweight [5]. Zhao et al. established a finite element model of the press frame and proposed a two-stage topology optimization method to optimize the frame structure, which reduced the volume by 13.66% while ensuring the frame performance [6]. P. Satheesh Kumar Reddy et al. optimized the design based on the tensile stiffness formula and strength-to-weight ratio characteristics of the solid shaft and hollow shaft. ...
In order to realize the lightweight design of mobile pump truck, this paper takes the frame of a certain type of mobile pump truck as the research object. The response surface method is used to carry out lightweight design of the longitudinal beam structure of the frame, and the finite element method is used to establish the finite element model to compare and analyze the optimized and original designs. The results show that the height, width and thickness of the optimized longitudinal beam section are reduced by 10mm, 11mm, and 0.8mm respectively, and the weight of the whole frame is reduced by 35.8kg. Before and after optimization, the displacement and stress changes of the frame are small in four motion situations, which meet the lightweight requirements of optimization design.
... Based upon results from mesh convergence study, the design domain contains a total of 978, 112 tetrahedral elements and 163, 273 nodes. This work uses Altair OptiStruct Òsoftware to solve Eqs. 1 and 2 [51]. The output from OptiStructÒis a density map over the design domain with densities for elements varying between 0-1, 0 for void, and 1 for a homogeneous isotropic solid. ...
Pelvic bone is a complex and robust load-bearing skeletal structure in the human body, the evolution of which might have been influenced by mechanical loads of daily activities like walking, upright standing, and running. Since the main function of skeletal bones is to provide rigidity to the body and provide hard surfaces for muscle attachment as well, in this work we propose a compliance minimization problem to determine whether material distribution guided by topology optimization yields a skeletal structure similar to the pelvic bone under same boundary conditions and volumetric constraints. As bone growth occurs in response to the mechanical loads acting on it, we consider the maximal loads that the pelvic bone may experience for a continued period of time, namely during running. The running gait cycle is divided into seven phases, and the objective function is a weighted combination of these seven phases. The optimal geometries are compared with the natural hemi-pelvis by measuring shape similarity using Procrustes analysis. Results show that the optimal geometries have good shape similarity in stance phases. We also explore the design space by considering a combination of sequence of phases which is an alternative to the weighted multiple load-case objective function. In all cases, the optimal geometries are stiffer than the hip bone. To validate this result, we conducted compression test experiments on selected optimal geometries and natural hemi-pelvis model of same material and found that the experimental results prove that topology optimization based optimal geometries are indeed more stiff than the natural hemi-pelvis geometry.
... Zhao et. al. [7] menerapkan analisa dengan metode elemen hingga dan studi topologi optimasi pada blanking press frame kapasitas 12000KN dengan perangkat lunak Hypermesh. Tujuan dari penelitian ini adalah mendapatkan desain fall block dengan berat yang ringan dengan mempertahankan kekakuaan strukturnya. ...
Desain fall block yang berat akan menambah beban kerja crane saat operasi, selain itu juga menambah beban diatas dek kapal yang akan sangat berpengaruh terhadap stabilitas kapal, oleh karena itu perlu dilakukan kajian untuk mengurangi berat blok sehingga kinerja crane lebih optimal untuk mengangkat beban. Optimasi topologi telah sukses dalam beberapa dekade terakhir, metode analisis elemen hingga (FEA) dan studi eksperimental telah dilakukan dalam menyelidiki dan mengoptimalkan struktur lambung kapal. Tujuan dari penelitian ini adalah mendapatkan desain fall block dengan berat yang ringan dengan mempertahankan kekakuaan strukturnya. Optimasi topologi dilakukan menggunakan perangkat SolidWorks Simulation yang berbasis metode elemen hingga, yang selanjutnya akan dapat dibandingkan perubahan berat desain awal dengan desain hasil optimasi serta perubahan tegangan sebelum dan sesudah dilakukan optimasi. Dari hasil optimasi topologi didapatkan penurunan massa sebesar 15.21 % dengan berat menjadi 338.54 kg. Selain itu tegangan Von Mises maksimum pada variasi turun 1.24% menjadi 26.22 MPa. Akibat dari turunya nilai tegangan tersebut membuat nilai safety factor meningkat 1.25 % dari desain awal menjadi 9.53 yang dapat dikatakan nilai tegangan yang terjadi di desain baru masih dinyatakan aman.
... Songr et al. [5] optimizes the shape of the windlass base frame, not only can enhance its performance, however additionally to gain the reason of lowering energy consumption. Guan et al. [6] applies the finite element evaluation and topology optimization examine to the 12000KN fine blanking press body with Altair Hypermesh software. Furthermore, the optimum design of the anchor mooring winch support bracket may be regarded as a continuum structure optimization problem. ...
The weight of the deck machinery greatly affects the position of the small ship’s center of gravity so that it also affects the stability of the ship. Therefore, it is necessary to conduct optimization studies to reduce the weight of ship deck machinery, especially anchor mooring winch, by reducing the weight of ship deck machinery will lower the position of the center of gravity of ship so that can improve ship stability. This paper presents the effects of a topology optimization examination based on the finite element evaluation on anchor mooring winch support bracket using the SolidWorks Simulation module. The main intention to examine is to optimize the general weight of the anchor mooring winch support bracket via way of means of thinning specific regions of the anchor mooring winch support bracket in keeping with the calculated minimum strain energy. The topology optimization algorithm that is used in the current study gives an optimal structural shape of the support bracket of the anchor mooring winch with the largest stiffness, considering the given quantity of mass so that it will be eliminated from the preliminary layout space. The complete sequence of steps for carrying out the topology control optimization study is shown, taking into account the constraints arising from the construction features and the method of manufacturing the support bracket of the anchor mooring winch. The layout became carried out, and the effects have been provided via way of means of evaluating the preliminary version and the optimized version. As the result of topology optimization study, its stress was increased by about 4MPa and mass was reduced by about 15kg in comparison with the initial design.
... Compared with the conventional blanking process, a special designed fine-blanking press was required for this process, which can provide at least three separately forces, namely blanking force, blank holder force and counter punch force [3]. Now, almost all of the FB press is hydraulic machine with the capacity of 3200kN ~ 12000kN [4], and the forming efficiency is about 30~70 times per minute with punch stroke of 40mm. With the increasing of huge market demand for the mid-thick sheet metal parts, the FB efficiency should be further improved, which the target is about 200 times per minute or higher. ...
The fine-blanking process as an advanced sheet metal forming process has been widely applied in industry. However, specially designed equipment is required for this process. In this paper, a novel mechanical servo high-speed fine-blanking press with the capacity of 3200 kN is proposed, and the vibration control for this machine is researched to achieve the requirement of fine-blanked parts of high dimensional accuracy, since the vibration of the fine-blanking machine will cause the machining displacement error and reduce the machining accuracy. Self-adaptive feed-forward control is used to simulate the active vibration control of the mechanical fine-blanking machine. The vibration control principle of the fine-blanking machine is described, and the control algorithm is established. At the same time, the mechanical vibration model of the fine-blanking machine as the controlled object is established, and the parameters of the excitation input and the mechanical model are obtained by the fine-blanking finite element simulation and the experiments of the vibration measurement of the press. Finally, the numerical simulation and analysis of active vibration control based on MATLAB are carried out. The results show that the control effect is good, and the vibration response is effectively reduced, thus greatly increasing the processing accuracy, saving a significant amount of energy, and reducing the energy consumption and defective rate.
... Based on research into static and dynamic analyses of mechanical components and structures, ref. [20][21][22][23][24][25] investigated some effective structure optimization methods for improving the performance of machines. However, investigations into the COF machine are mainly investigations of the deformation mechanism, forging force and kinematic mechanism of COF [26][27][28][29][30][31][32][33], and few investigations into the static performance and dynamic performance of the COF machine have been carried out. ...
In cold orbital forging (COF) processes, large stress, displacement and vertical vibration of the COF machine are bad for the quality of the part and the fatigue life of the COF machine. It is necessary to investigate the static and dynamic performance of the COF machine and provide methods for reducing the stress, displacement and vertical vibration of the COF machine. In this paper, finite element analysis, theoretical analysis, numerical simulation and experimental analysis were applied to study the static and dynamic performance of a 6300 KN COF machine. The static and dynamic analyses were verified effectively by carrying out strain and vertical vibration test experiments. In the static analysis, the large stress and displacement positions of the COF machine were mainly distributed near the working table and the junction between the working table and the column. Large stress and displacement will be bad for the quality of the part and the fatigue life of the COF machine. Structural optimizations of the COF machine include ribbed plates on the working table and beam. This structural optimization method of the COF machine obviously reduced the stress and displacement of the COF machine. When the angular velocities of the eccentric rings were 8π rad/s, the vertical vibration of the swing shaft is a low-frequency vibration. The existence of absorber obviously reduced the vertical vibration of the COF machine.
... Taking the mobile port crane as the optimization object, Jang et al. (2014) utilized topological optimization of sensitivity and shape optimization to obtain the optimal dimensions of Mobile Harbor Cranes. Zhao et al. (2016) designed and optimized the frame structure of the 12,000 kN precision punching machine, using the topological optimization method. The weight of the frame decreased, and the performance of the machine increased compared with those of the original frame. ...
... These studies show that topology optimization technology has been well applied in structural design engineering. However, the removal of some structural components greatly increases the difficulty of the actual production process (Zhao et al. 2016). In this paper, the method of optimizing control parameters and the manufacturing constraints is studied to improve product manufacturability under the premise of satisfying the optimization objective. ...
Biaxial tensile testing machines are used to improve accuracy of yield loci and constitutive model for sheet materials. The frame of these machines is the main load-bearing structure significantly affecting the machine accuracy. However, the available loading frames are too heavy to be practical for popularization and application. To reduce both the total weight of the frame and install consumption, this study develops a design method of stepwise multi-stage topology optimization based on the solid isotropic microstructures with penalization (SIMP) method. First, the validity of the finite element model during the optimization is verified by experiments. Next, the design method of stepwise multi-stage topology optimization is proposed based on the results of conventional topology optimization and the influence law of key parameters. This method is then applied to the topological optimization design of frames for a biaxial tensile testing machine. Finally, the optimized frame is manufactured, and biaxial tensile tests are conducted on the designed machine. The measurement of frame deformations shows that the frame weight is decreased by 19.5% compared with that of the initial design and that the frame stiffness meets design requirements. These results prove the effectiveness of the proposed method.
... Unfortunately, the optimization result featured with material stacks was difficult to be interpreted into a frame structure welded by thick plates. To deal with this problem, Zhao et al. proposed a two-stage topology optimization procedure to optimize the fine-blanking press frame, which was proved to be appropriate and feasible [24]. However, the interpreted structure was irregular and complicated, which was difficult for manufacturing and transporting. ...
... Constraints were applied on the nodes that site in the bolt hole (all DOFs restrained) and the surfaces contacted with the ground (only the DOFs of Z-direction displacement were restrained). A previous work [24] compared two kinds of loading methods for the fine-blanking press frame: 1) forces were uniformly distributed to the load-bearing nodes and 2) the loaded surfaces were assumed as rigid surfaces, on which a concentrated force was applied. The simulation result showed that the latter is more consistent with the experiment result. ...
The fine-blanking press, which has been widely used in the sheet-cutting industry, is high-end equipment. The frame is a core component of the fine-blanking press. In this paper, the sensitivity analysis and size optimization method were used to optimize a fine-blanking press frame. First, a shell element model of the frame was established to analyse the mechanical properties of the initial frame. Then, the mathematical expressions for sensitivity analysis and size optimization of the frame were formulated. Based on the established model, the response sensitivities for plate thicknesses were analysed, and a 12.94 % weight reduction was achieved through size optimization. Moreover, the effect of material distribution on dynamic performance was investigated. The result indicated that for a constrained structure, distributing material close to the constraint location increases the modal frequencies.
