The 3-D welding manipulator use the hardware of motion controller、IPC 、 stepping motor system and so on, motion control card was used to control three stepping motor, the curved beam design a append structural with“ ”shape to avoid splash in the welding process. In software development, use windows multithread technology to make sure the gesture demand of welding gun perpendicular to welder all the time. Practice has proved, the manipulator can interpolate welding curve and realize accuracy controlling of welding-torch position and gesture in the whole welding process.
Roll forging process for automobile front axle has been simulated by using a rigid viscoplastic finite element method, force-time curve have been obtained and analyzed. On the basis of simulation result, typical characteristics of roll forging process have been explained. It concluded that simulation results could guide the development of roll forging and die design for automobile front axle.
According to the characters, technological condition and requirements of automotive front axle forging, both the process of exact roll-forging billet and die design are studied, as the result, roll- forging die of front axle billet, pre-completed roll-forging die and final roll-forging die are design respectively, finally the groove with hat cross-section is analyzed and top pressure rolling method is proposed during blank-making roll-forging process. The precision rolling forging performing deformation process of automobile front axle is simulated with finite element software Deform-3D by using 3D thermo-mechanical coupled rigid plastic FEM. The metal flow process, equivalent stress and strain field, temperature field and load status of rolling die are analyzed, and they are consistent with experiments. This provides a dependable theoretical basis for understanding the deforming mechanism and selecting reasonable parameters for the precision rolling forging performing of front axle.
According to the characters, technological condition and requirements of automotive front axle forging, the advantage of the roll forging and integral die forging complex process for automobile front axle were explained, including the determination of roll- forging parts chart, selection of billet dimension, decision of roll- forging steps, special roller- shaped design of typical section, and the front sliding parameter is calculated, its effect to length of forging parts gets analyzed. In this paper, taking NHR front axle as an instance, both the process of exact roll- forging billet and die design are studied, as the result, roll- forging die、 performing roll- forging die and final roll-forging die are design respectively. The process for roll forging was simulated by the three dimensional finite element analyses under isothermal condition, and metal flow procedure and force time curve were obtained. The connection among metal flow law and die cavity design and forming load were also analyzed. To verify the reliability of the simulation, the results for profile was compared with the tested forging part, showing that metal flow law of both are coincident and FE simulation of roll forging is accurate. Practice testify that FE simulation of roll forging for front axle can reduce the time of process design and procedure debugging and be helpful to response the market demand.
Basis on the AIC selection smallest regularization, flattest regularization and smoothest regularization resolution result are compared at different noise level. The result explore the insight into how to solve the inversion problem when noise increase gradually. Some analysis has been done to decide the ability of the three methods on handling the data gaps. Each method has their special way to invert the data and give inference for data gaps with zero padding, linearize interpolation or smooth way. The results of the study is very important ,especially in the applied technology problem such as geophysics, geodetics, and so on.
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