Lightweight Design Optimization of Large-Tonnage Hydraulic Press Body Structure

Zhang, Wei; Lu, Baochun; Guo, Fangwei; Ma, Chaoli

doi:10.4028/www.scientific.net/amr.748.406

Cited by 2 publications

(1 citation statement)

References 3 publications

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“…The internal manufacturing structure of the slider was optimized to reduce its mass while considering the manufacturability. Zhang et al optimized the structure of a large hydraulic press to realize manufacturing cost reduction, energy saving, and performance degradation minimization [16,78]. The energy consumption of the press can be significantly reduced with considerable mass reduction by the structure optimal design for press.…”

Section: Energy Efficiency Improvement and Energy Saving Methods For mentioning

confidence: 99%

A Review on Energy Consumption, Energy Efficiency and Energy Saving of Metal Forming Processes from Different Hierarchies

Gao

et al. 2019

Processes

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Energy efficiency improvement and environmental impact reduction are emerging issues in the manufacturing industry. Aside from cutting, metal forming is also an important process in manufacturing. Metal forming is energy intensive because of the low energy efficiency of the used metal forming press. Although many literature reviews focused on the energy reduction and energy efficiency of machine tools, a comprehensive literature review of metal forming processes remains lacking because of the great difference between cutting machines and forming equipment. In addition, methods for energy efficiency and energy-saving still need to be promoted in metal forming. In this review, a novel hierarchy of the metal forming system was presented to describe the relationship among the equipment, process, and manufacturing system, providing a guideline of methods for energy efficiency and saving in metal forming. Then, existing energy consumption modeling and estimation theories and methods were discussed from two aspects. One is energy monitoring and modeling of metal forming equipment, and the other is process energy analysis of metal forming based on different parameters. On the basis of the hierarchy of the metal forming system, the present methods and technologies aiming to promote energy efficiency and energy saving effects were discussed from the aspects of equipment design and control, process optimization, and scheduling management and use. Thus, this review may serve as a reference for the decision-making of producers and managers to realize energy efficiency and energy saving at the system level. In addition, the major points that need attention are accurate energy models and control of forming equipment as well as the integrated optimization of equipment, process, and scheduling.

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Section: Energy Efficiency Improvement and Energy Saving Methods For mentioning

confidence: 99%

A Review on Energy Consumption, Energy Efficiency and Energy Saving of Metal Forming Processes from Different Hierarchies

Gao

et al. 2019

Processes

View full text Add to dashboard Cite

show abstract

Design Optimization Approach of a Large-Scale Moving Framework for a Large 5-Axis Machining Center

et al. 2018

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The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures. However, this kind of substitution is generally believed to be difficult because foam-filled sandwich structures usually show nonlinear characteristics and must balance the moving mass, material costs, and structural stiffness. In the present study, we proposed a design optimization approach for a large-scale moving framework in a large 5-axis machining center (L5AMC) considering large dimensions in the x, y, and z work space and high machining speed with the aim of minimizing the displacements of the milling head. An improved approach, named the 3-step design optimization, was executed to obtain the optimum framework structures to solve the contradiction between the moving mass, material costs, and structural stiffness. This approach was based on multi-objective optimization and finite element analysis. The structural stiffness of the framework after optimization increased by 89% compared with before optimization although the mass increased by 6% and the material costs increased by 9%. A finite element simulation under four given operational loads showed that the displacements of the milling head were all less than the design requirement of 0.25 mm. The results indicated that the proposed 3-step design optimization approach for the optimal design of a large-scale moving framework was feasible and successful. A 40 m × 6 m × 4 m L5AMC prototype was manufactured, and the actual verification results indicated that the large-scale moving framework fully met the design requirements of the L5AMC and reduced energy consumption.

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Lightweight Design Optimization of Large-Tonnage Hydraulic Press Body Structure

Cited by 2 publications

References 3 publications

A Review on Energy Consumption, Energy Efficiency and Energy Saving of Metal Forming Processes from Different Hierarchies

A Review on Energy Consumption, Energy Efficiency and Energy Saving of Metal Forming Processes from Different Hierarchies

Design Optimization Approach of a Large-Scale Moving Framework for a Large 5-Axis Machining Center

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