Optimizing the Design of Press Fuselage Using Finite Element Method
The press fuselage is a crucial component of the press, bearing the weight of all parts and resisting various forces during the manufacturing process. A well-designed fuselage ensures the press operates efficiently, with improved machining precision and extended lifespan of the mold. However, traditional design methods often lead to an imbalance between weight reduction and rigidity, resulting in a suboptimal design. In this article, we explore the novel application of finite element analysis (FEA) to optimize the design of the press fuselage.
Establishing the FEA Model
To conduct FEA, a three-dimensional geometric model of the fuselage was created using the SolidEdge software. The generated model was then imported into the Nastran software for finite element analysis.
The fuselage is a complex frame structure composed of steel plates, welded together by side plates, reinforcement ribs, support plates, and connection plates. To facilitate grid division and enhance FEA efficiency, a reasonable division of the fuselage model was made. The resulting model is shown in Figure 1.
Boundary Conditions and Loading
To simplify the analysis, several assumptions were made:
- The fuselage is a closed frame structure.
- The weight of the fuselage, as well as the forces between the guideways and slider, and the impact of the foundation on the fuselage, are neglected, and the displacement of all nodes is fully constrained, ensuring that the rigid body displacement of the structure is eliminated.
- The effect of tangential force and centripetal force on the fuselage when the machine is in operation is ignored, as these forces have a minimal impact on the overall behavior of the fuselage.
Material Properties and Meshing
The steel plates used in the fuselage have a Young’s modulus of 2.08 GPa, a Poisson’s ratio of 0.29, and a density of 7.8 g/cm3. A tetrahedral element with four linear nodes was employed for meshing, providing each unit with four faces and four nodes, with each node having three degrees of freedom of translation. The total number of grids divided by the fuselage is 18,811, with 6,701 nodes. The finite element model of the fuselage is shown in Figure 2.
Calculation Results and Analysis
The calculation results were verified using the NX Nastran solver, and the equivalent constraint cloud diagram after subjecting the fuselage to a nominal load was obtained (Figure 3). The equivalent constraint cloud diagram (Figure 4) was generated using the software post-processing.
From the analysis, the following conclusions can be drawn:
- The maximum deformation of 0.335 mm is observed at the upper end of the front bearing, meeting the press design requirements. Deformations in other areas are relatively small, ranging from 0.05 mm to 0.27 mm, and are distributed evenly.
- The equivalent stress cloud diagram indicates that the constraint concentration is mainly observed at the rounded corners of the power windows on the left and right sides of the fuselage, the rounded corners of the transition from the support plate to the ouchette, and at the upper and lower ends of the front and rear holes. The maximum constraint of 47.1 MPa at the upper end of the front bearing hole is within the elastic limit of the steel plate.
In conclusion, the FEA results demonstrate that the constraint and deformation distribution in the fuselage can be precisely calculated using the finite element software FEMAP with Nastran, providing valuable insights for optimal design of the press fuselage. By applying FEA, designers can enhance the design of the press fuselage, ensuring optimal performance, improved machining precision, and extended lifespan of the mold.
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