噴涂機(jī)器人的結(jié)構(gòu)設(shè)計(jì),噴涂機(jī)器人的結(jié)構(gòu)設(shè)計(jì),噴涂,機(jī)器人,結(jié)構(gòu)設(shè)計(jì) 噴涂機(jī)器人的結(jié)構(gòu)設(shè)計(jì) 中文摘要： 英文摘要 目錄 1.前言 2電動(dòng)機(jī)的設(shè)計(jì) （1）大臂電動(dòng)機(jī)的設(shè)計(jì) （2）基座電動(dòng)機(jī)的設(shè)計(jì) 3軸的設(shè)計(jì)和校核 （1）基座傳動(dòng)軸的設(shè)計(jì) （2）軸的強(qiáng)度校核 （3）基座傳動(dòng)軸上零件校核 …………………………….. ………………………………….. ………………………………………. 前言 首先我介紹一下機(jī)器人產(chǎn)生的背景，機(jī)器人技術(shù)的發(fā)展，它應(yīng)該說(shuō)是一個(gè)科學(xué)技術(shù)發(fā)展共同的一個(gè)綜合性的結(jié)果，同時(shí)，為社會(huì)經(jīng)濟(jì)發(fā)展產(chǎn)生了一個(gè)重大影響的一門科學(xué)技術(shù)，它的發(fā)展歸功于在第二次世界大戰(zhàn)中各國(guó)加強(qiáng)了經(jīng)濟(jì)的投入，就加強(qiáng)了本國(guó)的經(jīng)濟(jì)的發(fā)展。比如說(shuō)日本，戰(zhàn)后以后開始進(jìn)行汽車的工業(yè)，那么這時(shí)候由于它人力的缺乏，它迫切需要一種機(jī)器人來(lái)進(jìn)行大批量的制造，提高生產(chǎn)效率降低人的勞動(dòng)強(qiáng)度，這是從社會(huì)發(fā)展需求本身的一個(gè)需求。另一方面它也是生產(chǎn)力發(fā)展的需求的必然結(jié)果，也是人類自身發(fā)展的必然結(jié)果，那么人類的發(fā)展隨著人們逐漸的這種社會(huì)發(fā)展的情況，人們?cè)絹?lái)越不斷探討自然過(guò)程中，在改造自然過(guò)程中，認(rèn)識(shí)自然過(guò)程中,來(lái)需求能夠解放人的一種奴隸。那么這種奴隸就是代替人們?nèi)ツ軌驈氖聫?fù)雜和繁重的體力勞動(dòng)，實(shí)現(xiàn)人們對(duì)不可達(dá)世界的認(rèn)識(shí)和改造，這也是人們?cè)诳萍及l(fā)展過(guò)程中的一個(gè)客觀需要。但另一方面，盡管人們有各種各樣的好的想法，但是它也歸功于電子技術(shù)，計(jì)算機(jī)技術(shù)以及制造技術(shù)等相關(guān)技術(shù)的發(fā)展而產(chǎn)生了提供了強(qiáng)大的技術(shù)保證。 機(jī)器人有三個(gè)發(fā)展階段，那么也就是說(shuō)，我們習(xí)慣于把機(jī)器人分成三類，一種是第一代機(jī)器人，那么也叫示教再現(xiàn)型機(jī)器人，它是通過(guò)一個(gè)計(jì)算機(jī)，來(lái)控制一個(gè)多自由度的一個(gè)機(jī)械，通過(guò)示教存儲(chǔ)程序和信息，工作時(shí)把信息讀取出來(lái)，然后發(fā)出指令，這樣的話機(jī)器人可以重復(fù)的根據(jù)人當(dāng)時(shí)示教的結(jié)果，再現(xiàn)出這種動(dòng)作，比方說(shuō)汽車的點(diǎn)焊機(jī)器人，它只要把這個(gè)點(diǎn)焊的過(guò)程示教完以后，它總是重復(fù)這樣一種工作，它對(duì)于外界的環(huán)境沒(méi)有感知，這個(gè)力操作力的大小，這個(gè)工件存在不存在，焊的好與壞，它并不知道，那么實(shí)際上這種從第一代機(jī)器人，也就存在它這種缺陷，因此，在20世紀(jì)70年代后期，人們開始研究第二代機(jī)器人，叫帶感覺(jué)的機(jī)器人，這種帶感覺(jué)的機(jī)器人是類似人在某種功能的感覺(jué)，比如說(shuō)力覺(jué)、觸覺(jué)、滑覺(jué)、視覺(jué)、聽覺(jué)和人進(jìn)行相類比，有了各種各樣的感覺(jué)，比方說(shuō)在機(jī)器人抓一個(gè)物體的時(shí)候，它實(shí)際上力的大小能感覺(jué)出來(lái)，它能夠通過(guò)視覺(jué)，能夠去感受和識(shí)別它的形狀、大小、顏色。抓一個(gè)雞蛋，它能通過(guò)一個(gè)觸覺(jué)，知道它的力的大小和滑動(dòng)的情況。 那么第三代機(jī)器人，也是我們機(jī)器人學(xué)中一個(gè)理想的所追求的最高級(jí)的階段，叫智能機(jī)器人，那么只要告訴它做什么，不用告訴它怎么去做，它就能完成運(yùn)動(dòng)，感知思維和人機(jī)通訊的這種功能和機(jī)能，那么這個(gè)目前的發(fā)展還是相對(duì)的只是在局部有這種智能的概念和含義，但真正完整意義的這種智能機(jī)器人實(shí)際上并沒(méi)有存在，而只是隨著我們不斷的科學(xué)技術(shù)的發(fā)展，智能的概念越來(lái)越豐富，它內(nèi)涵越來(lái)越寬。 機(jī)器人有三個(gè)發(fā)展階段，那么也就是說(shuō)，我們習(xí)慣于把機(jī)器人分成三類，一種是第一代機(jī)器人，那么也叫示教再現(xiàn)型機(jī)器人，它是通過(guò)一個(gè)計(jì)算機(jī)，來(lái)控制一個(gè)多自由度的一個(gè)機(jī)械，通過(guò)示教存儲(chǔ)程序和信息，工作時(shí)把信息讀取出來(lái)，然后發(fā)出指令，這樣的話機(jī)器人可以重復(fù)的根據(jù)人當(dāng)時(shí)示教的結(jié)果，再現(xiàn)出這種動(dòng)作，比方說(shuō)汽車的點(diǎn)焊機(jī)器人，它只要把這個(gè)點(diǎn)焊的過(guò)程示教完以后，它總是重復(fù)這樣一種工作，它對(duì)于外界的環(huán)境沒(méi)有感知，這個(gè)力操作力的大小，這個(gè)工件存在不存在，焊的好與壞，它并不知道，那么實(shí)際上這種從第一代機(jī)器人，也就存在它這種缺陷，因此，在20世紀(jì)70年代后期，人們開始研究第二代機(jī)器人，叫帶感覺(jué)的機(jī)器人，這種帶感覺(jué)的機(jī)器人是類似人在某種功能的感覺(jué)，比如說(shuō)力覺(jué)、觸覺(jué)、滑覺(jué)、視覺(jué)、聽覺(jué)和人進(jìn)行相類比，有了各種各樣的感覺(jué)，比方說(shuō)在機(jī)器人抓一個(gè)物體的時(shí)候，它實(shí)際上力的大小能感覺(jué)出來(lái)，它能夠通過(guò)視覺(jué)，能夠去感受和識(shí)別它的形狀、大小、顏色。抓一個(gè)雞蛋，它能通過(guò)一個(gè)觸覺(jué)，知道它的力的大小和滑動(dòng)的情況。 那么第三代機(jī)器人，也是我們機(jī)器人學(xué)中一個(gè)理想的所追求的最高級(jí)的階段，叫智能機(jī)器人，那么只要告訴它做什么，不用告訴它怎么去做，它就能完成運(yùn)動(dòng)，感知思維和人機(jī)通訊的這種功能和機(jī)能，那么這個(gè)目前的發(fā)展還是相對(duì)的只是在局部有這種智能的概念和含義，但真正完整意義的這種智能機(jī)器人實(shí)際上并沒(méi)有存在，而只是隨著我們不斷的科學(xué)技術(shù)的發(fā)展，智能的概念越來(lái)越豐富，它內(nèi)涵越來(lái)越寬。 我設(shè)計(jì)的噴吐機(jī)器人主要運(yùn)用于房屋墻壁的噴漆，汽車表面噴途等用途。我 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 本論 2.2.1電動(dòng)機(jī)的設(shè)計(jì) 假設(shè)手腕的最大負(fù)荷重量3kg，初估腕部的重量3kg，最大運(yùn)動(dòng)速度V=1.5m/s 功率P=fv=mgv=6×10×1.5=90kw 取安全系數(shù)為1.2， 考慮到傳動(dòng)損失和摩擦，最終的電機(jī)功率P=110W。 查表選擇75BF004型號(hào)反應(yīng)式步進(jìn)電動(dòng)機(jī)。 具體參數(shù)如下表 型號(hào) 相數(shù) 步距角 最大精轉(zhuǎn)矩 安裝外徑 長(zhǎng)度 軸徑 重量 75BF004 3 1.5 0.882NM 75mm 75mm 6mm 1.58kg 小臂減速比的確定 求角速度 W＝==3.75r/s 其中W為角速度（r/s） V為運(yùn)動(dòng)速度（m/s） R為小臂連桿的長(zhǎng)度（400mm） 在求實(shí)際轉(zhuǎn)速 N＝=36r/min 最后求得總傳動(dòng)比：i= 步進(jìn)電動(dòng)機(jī)轉(zhuǎn)速為 n＝ 其中為步距角 f為控制脈沖頻率 由電動(dòng)機(jī)型號(hào)查表求得f＝2500hz 則 n＝==625r/min 則i==17.3 取i整＝17 查表采用行星齒輪結(jié)構(gòu)的 諧波減速器具體機(jī)構(gòu)及參數(shù)如下所示 ： 行星齒輪減速器 自齒 輸出端軸承 滾珠軸承 最大 允許軸向載荷 150N 最大允許安裝力 300N 推薦輸入速度 800rpm 減速比 17：1 輸出最大轉(zhuǎn)矩 15N.M 允許瞬間輸出轉(zhuǎn)矩 22.5N.M 具體安裝尺寸見下圖所示： 2.2.2機(jī)座電動(dòng)機(jī)和大臂電動(dòng)機(jī)的結(jié)構(gòu)設(shè)計(jì)同小臂采用相同原理 大臂電動(dòng)機(jī)的設(shè)計(jì)： 初步估計(jì)大臂電動(dòng)機(jī)的 負(fù)載為16kg 最大運(yùn)動(dòng)速度為1.5m/s 同理求得P=288W 查相關(guān)手冊(cè)選步進(jìn)電動(dòng)機(jī)的型號(hào)為：90BF003 具體參數(shù)如下： 電動(dòng)機(jī)型號(hào) 相數(shù) 步距角 最大靜轉(zhuǎn)矩 最大啟動(dòng)功率 90BF003 3 1.5 1.96 1500HZ 質(zhì)量 外徑 長(zhǎng)度 軸徑 最大運(yùn)行頻率 4.2kg 90mm 125mm 9mm 8000hz 由以上數(shù)據(jù)可得步進(jìn)電動(dòng)機(jī)的轉(zhuǎn)速為 由公式n＝==2000r/min 又由W===2.14r/s 實(shí)際轉(zhuǎn)速n’==20r/min 由公式得 i總＝==100 查表采用行星齒輪結(jié)構(gòu)的諧波減速器，具體參數(shù)如下表 ： 行星齒輪減速器 直齒 輸出端軸承 滾珠軸承 最大允許軸向載荷 250N 最大安裝力 410N 推薦輸入速度 8000rpm 減速比 100：1 輸出最大轉(zhuǎn)矩 26N.M 允許瞬間輸出轉(zhuǎn)矩 36N.M 具體安裝尺寸見下圖： 2.23機(jī)座電動(dòng)機(jī)的設(shè)計(jì) 初步估計(jì)電動(dòng)機(jī)最大載荷重量為m=30kg 最大運(yùn)動(dòng)速度V＝1.5m/s 功率P＝FV=mgv=30×10×1.5＝450W 取安全系數(shù)為1.2 則P’＝P×1.2＝540W 考慮到傳動(dòng)損失和摩擦，最終的電動(dòng)機(jī)功率確定為P額=560W 查表找出電動(dòng)機(jī)的具體參數(shù)如下表 電動(dòng)機(jī)型號(hào) 相數(shù) 步距角 最大靜轉(zhuǎn)矩 最大啟動(dòng)功率 90BF001 4 1.8 3.92 2000HZ 質(zhì)量 外徑 長(zhǎng)度 軸徑 最大運(yùn)行頻率 4.5kg 90mm 145mm 9mm 8000hz 求基座電動(dòng)機(jī)的諧波減速比： 由公式n＝==2400r/min 又由基座傳動(dòng)軸與噴槍幾乎處在 同一直線的特殊位置故： W===15r/s 實(shí)際轉(zhuǎn)速n’===143 最后求得總傳動(dòng)比 i總＝==16.7 取i整＝17 基座電動(dòng)機(jī)也采用同諧波減速器相聯(lián)一體的結(jié)構(gòu)。具體參見下圖，安裝尺寸見下： 行星齒輪減速器 直齒 輸出端軸承 滾珠軸承 最大允許軸向載荷 250N 最大安裝力 410N 推薦輸入速度 8000rpm 減速比 17：1 輸出最大轉(zhuǎn)矩 26N.M 允許瞬間輸出轉(zhuǎn)矩 36N.M 3.軸的設(shè)計(jì)和校核 軸的結(jié)構(gòu)決定與受力情況，軸上零件的布置和固定方式，軸承的類型和尺寸，軸的毛坯和制造，裝配工藝，以及運(yùn)輸，安裝等條件，軸的結(jié)構(gòu)，應(yīng)使軸受力合理，避免或減輕應(yīng)力集中。 3.1基座傳動(dòng)軸的設(shè)計(jì) 取軸的材料為45鋼。調(diào)制處理。 a.軸經(jīng)同電動(dòng)機(jī)輸出軸相同大小故d=9mm b. 各段軸徑的確定 初估軸徑后，就可按照軸上零件的安裝順序從出開始逐段確定軸徑，上面是軸段1的直徑。 軸段1上 用套筒開通鍵和電動(dòng)機(jī)輸出軸相連。由于套筒幾乎不受軸向力故在套筒上開一緊盯螺釘螺釘采用。 軸段2上安裝套筒。右端用軸肩固定，考慮到軸的強(qiáng)度取軸徑＝18mm 軸段3上要安裝軸承，其直徑應(yīng)該便于軸承安裝，，故取軸段3的直徑為d=30mm 軸段4左端用軸肩固定軸承，有軸承的安裝尺寸可得＝40mm。根據(jù)尺寸結(jié)構(gòu)和便于控制軸段4末端采用圓孔型結(jié)構(gòu)。具體尺寸見圖。 C. 各段長(zhǎng)度的確定 根據(jù)套筒及箱體結(jié)構(gòu)的尺寸取＝40mm 考慮到套筒長(zhǎng)及箱體的長(zhǎng)度?。?8mm 根據(jù)軸承寬度?。?4mm 由機(jī)器人的噴涂范圍及基座總長(zhǎng)等因素取＝126mm 軸的結(jié)構(gòu)見下圖所示： 3.2軸的強(qiáng)度校核 軸在初步完成結(jié)構(gòu)設(shè)計(jì)后，進(jìn)行校核計(jì)算，計(jì)算準(zhǔn)則是滿足軸的強(qiáng)度或剛度要求，進(jìn)行軸的強(qiáng)度校核計(jì)算時(shí)，應(yīng)根據(jù)軸的具體受載及應(yīng)力情況，采取相應(yīng)的方法，并恰當(dāng)?shù)剡x取其許用應(yīng)力。 a 計(jì)算軸上的轉(zhuǎn)矩T 主軸上的傳遞功率 ＝==0.7kw T=9.55** =9.55**=4.67*N b 軸的受力分析 軸傳遞的轉(zhuǎn)矩：=4.67*N=9.55** c 按彎矩合成強(qiáng)度校核軸的強(qiáng)度 （1）。繪制軸受力簡(jiǎn)圖。見圖a （2）。繪制垂直面彎矩圖b 軸承支撐力 =mg=32*10=320 又有*L=* = 計(jì)算彎矩 截面C右側(cè)彎矩 NM 截面C左側(cè)彎矩 NM d 繪制水平面彎矩圖 由于軸承水平面幾乎不受外力?？梢院雎圆凰恪? e 繪制彎矩圖 NM NM f 繪制轉(zhuǎn)矩圖 轉(zhuǎn)矩產(chǎn)生的扭剪應(yīng)力按脈動(dòng)循環(huán)變化 ?。?.6 截面C處的當(dāng)量彎矩為 g 校核危險(xiǎn)截面C的強(qiáng)度 故滿足強(qiáng)度要求 3.3基座傳動(dòng)軸上零件的校核 3.31鍵的校核： 根據(jù)軸徑的大小選擇鍵的類型， 由GB1096-79查表取鍵的規(guī)格：b*h=3*3 取鍵的系列長(zhǎng)度L=12mm 鍵的材料選用45剛 校核擠壓強(qiáng)度： 又有L=12-3=9mm 。 查表求得許用擠壓應(yīng)力＝(120－150)MP 故 擠壓強(qiáng)度足夠 3.3.2傳動(dòng)軸上軸承的校核 滾動(dòng)軸承的主要失效形式為疲勞點(diǎn)蝕和塑性變形。滾動(dòng)軸承的計(jì)算準(zhǔn)為 針對(duì)疲勞點(diǎn)蝕進(jìn)行壽命計(jì)算，針對(duì)塑性變形進(jìn)行靜強(qiáng)度計(jì)算，對(duì)于轉(zhuǎn)速較承 除進(jìn)行壽命計(jì)算外還需要計(jì)算軸承的極限轉(zhuǎn)速。 課題中選用的軸承規(guī)格為：30206型。 具體參數(shù)如下表： 型號(hào) D d T B C 額定動(dòng)載荷 額定靜載荷 30206 62 30 17.5 16 14 41.2KN 29.5KN 如下圖所示： a. 求當(dāng)量動(dòng)載荷P: 對(duì)于只受徑向載荷為主的軸承，當(dāng)量動(dòng)載荷為： 其中＝3340N 查表得＝1.2 根據(jù)公式計(jì)算：=1.2*3340=4008N 軸承的壽命計(jì)算公式為： 查表得到：C=41200N 對(duì)于球類軸承=3 則有 ：＝＝116×1086＝125998>20000h 故滿足壽命要求。 b.軸承的精強(qiáng)度校核： 求當(dāng)量精載荷 由于軸承只承受徑向載荷，由于則 =17668.6 靜強(qiáng)度選擇軸承的計(jì)算公式為： 查表=2 則=3533.7N 查表后得到：=505*N 故滿足要求。 3.4大臂軸的結(jié)構(gòu)設(shè)計(jì) 軸的材料選擇45號(hào)剛，調(diào)制處理。 各段軸徑的確定 軸段1由于和電動(dòng)機(jī)配合故＝9mm 考慮到在軸段2上裝上套筒故取軸徑d=20mm 軸段3上安裝軸承，其直徑因該便于軸承的安裝，又因該符合軸承的內(nèi)徑系列。即軸段3的直徑和軸承型號(hào)的選則同時(shí)進(jìn)行，軸承型號(hào)為6..6型的深溝球軸承，故＝30mm 軸段4的右端固定軸承故?。?5mm 各段長(zhǎng)度的確定 各段長(zhǎng)度主要根據(jù)軸上零件的配合部分長(zhǎng)度確定，還和箱體及軸承蓋等零件又關(guān)。 考慮到套筒長(zhǎng)取軸段1＝30mm 軸段2上安裝套筒，取長(zhǎng)為26mm 根據(jù)軸承的尺寸取軸段3＝14mm 根據(jù)機(jī)器人的整體結(jié)構(gòu)取軸段4＝83mm 3.4.1 軸的強(qiáng)度校核 大臂傳動(dòng)軸式一個(gè)傳動(dòng)力矩的軸如下圖所使的結(jié)構(gòu)： a 軸上轉(zhuǎn)矩 主軸上傳遞的功率 又公式代入d＝9mm c=110 則 NM b 畫出垂直面彎矩圖（如下圖） 水平面的支撐反力： 軸承支撐反力，由 則軸承 支撐反力為： 計(jì)算彎矩，取截面C處研究對(duì)象。 經(jīng)計(jì)算： C 繪制水平面彎矩圖 由于水平面幾乎不受力的作用，故不予考慮。 d 繪制合成彎矩圖 e 繪制轉(zhuǎn)矩圖：如下圖所示 轉(zhuǎn)矩T＝9.55×＝5250NM f 繪制當(dāng)量彎矩圖 轉(zhuǎn)矩產(chǎn)生的扭剪應(yīng)力按脈動(dòng)循環(huán)變化 ?。?.6 截面C處的當(dāng)量彎矩為： ＝3150NM g 校核危險(xiǎn)截面強(qiáng)度 完全滿足要求。 3.5大臂上零件的校核 3.51軸段1上鍵的校核 由軸的直徑確定鍵的類型，根據(jù)GB1096-79選取鍵的類型 B*h=3*3 其中L=12mm 校核擠壓強(qiáng)度： ，又有L=12-3=9mm 又由轉(zhuǎn)矩T=5.25* 故 故強(qiáng)度滿足要求 3.5．2軸承的校核。 滾動(dòng)軸承的計(jì)算準(zhǔn)為 針對(duì)疲勞點(diǎn)蝕進(jìn)行壽命計(jì)算，針對(duì)塑性變形進(jìn)行靜強(qiáng)度計(jì)算，對(duì)于轉(zhuǎn)速較承 除進(jìn)行壽命計(jì)算外還需要計(jì)算軸承的極限轉(zhuǎn)速。 大臂傳動(dòng)軸選用的軸承規(guī)格為：6006型。 求當(dāng)量動(dòng)載荷 式中為徑向載荷 為軸向載荷 為載荷系數(shù) 由于軸承主要承受徑向載荷故當(dāng)量動(dòng)載荷為： 其中＝424.7N又根據(jù)工作條件查表得到＝1.2 則＝1.2×424.7＝509。64N 根據(jù)公式計(jì)算壽命： 查表C=10200N 對(duì)于球類軸承＝3 則＝66790.6>20000h 故滿足要求。 靜強(qiáng)度校核： 求當(dāng)量靜載荷 軸承主要承受徑向載荷，?。? 則＝293.04 靜強(qiáng)度校核選用公式: 查表取＝2 則有： 查表得到=50500N 則可得到：。符合靜強(qiáng)度要求。 箱體的設(shè)計(jì) 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 結(jié)論 》。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 ，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，，， 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 謝辭 在此我要特別感謝我們的指導(dǎo)教師常主任給我的無(wú)盡的幫助，對(duì)我的指導(dǎo)，陪伴我們做畢業(yè)設(shè)計(jì)，使我們能夠按時(shí)保質(zhì)的完成畢業(yè)設(shè)計(jì)，同時(shí)我還要感謝我同組的同學(xué)對(duì)我的幫助和大力支持，使我能夠盡可能在短的時(shí)間完成畢業(yè)設(shè)計(jì)。 參考文獻(xiàn) 〈〈機(jī)械設(shè)計(jì)基礎(chǔ)〉〉 〈〈機(jī)械制造技術(shù)基礎(chǔ)〉〉 〈〈機(jī)械制圖〉〉 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。。 附錄：六張圖紙 噴吐機(jī)器人的裝配圖 。。。。。。。。。。。。。。 。。。。。。。。。。。。 。。。。。。。。。。。。。。 。。。。。。。。。。。。。。。。 Simulation of the Effect of Process Parameters on Particle Velocity in Cold Spray Using Laval Nozzle with Nine Holes Chuanshao Liua, Yaohui Jinb and Jianxin Zhengc Henan Polytechnic University, Jiaozuo 454003,P.R.China , , Keywords: Cold spray; Simulation; Laval nozzle with nine holes; Particle velocity. Abstract. Simulations of the supersonic flow field inside and outside of the Laval nozzle with single hole and nine holes were carried out based on the computational fluid dynamics method. The effects of different standoff distance and particle diameter on impact velocity of Cu particle spraying from single hole and nine holes were investigated firstly. The results show that the particle velocity obtained with the nine holes nozzle is higher than that of the single hole nozzle under the same standoff distance, and the smaller the standoff distance, the higher the particle velocity may be obtained with the nine holes, and the higher particle velocity may be obtained with smaller particle diameter for particles with diameters of 1 15 m. Furthermore the effects of different spraying pressure and temperature on particle velocity of Cu particle spraying from the nine holes nozzle were also studied. And the simulations indicate that the higher the spraying pressure and temperature may make the particle spraying with greater velocity. Introduction The standoff distance (SoD) between the nozzle and the substrate is one of the important parameters in the cold spray process, and which influences the particle impact velocity directly. Many scholars have focused on this problem. Pattison 1 found that a bow shock was formed at the impingement zone between the supersonic jet and the substrate when the SoD was small, and the bow shock was detrimental to the process performance as it reduced the particle impact velocity. His study also showed that the deposition efficiency was closely related to the SoD, and the bow shock reduced deposition efficiencies by as much as 40% under the SoD is less than 60mm when using a custom-made helium nozzle, operating at 2.0 MPa and 20oC. Alkhimov 2 found that the thickness of the compressed layer which formed between the bow shock and substrate depended on SoD when spraying air and helium, and the smaller the SoD, the thicker the compressed layer. His research also showed that aluminum particles less than 5m in diameter could be decelerated obviously in the compressed layer. Gilmore 3 and Dykhuizen 4 also found that the particles less than 5m in diameter could be decelerated and even deflected away from the substrate by the bow shock. The Laval nozzle with nine holes was used in this study in order to reduce the adverse effects of bow shock on particle impact velocity so as to obtain the better spraying effects under the same conditions of the nozzle exit area compared with the Laval nozzle with single hole. Theoretical Models Mathematical model. Compressible flow is a very complex and comprehensive phenomenon, and the actual flow of the nozzle is non-constant isentropic flow in the actual conditions. The flow inside of the nozzle is considered as a steady isentropic flow in theory so as to simplify the simulation. The governing equations used to describe the process are as follows 5. Continuity equation: 0)( =+ ut ; Momentum equation: +=+ puuut )()( ; Advanced Materials Research Vols. 314-316 (2011) pp 78-81 Online available since 2011/Aug/16 at (2011) Trans Tech Publications, Switzerland doi:10.4028/ All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP, . (ID: 222.88.196.201-26/08/11,01:28:10) Energy equation: )()( Tkupete D +=+ ; Equation of state: p=RT Where u, p, and T represent the flow velocity, pressure and temperature; , , and k represent the flow density, viscous stress tensor and thermal conductivity, respectively; e, D are the stagnation internal energy per unit volume and viscous dissipation, respectively. Particles can be considered as discrete phase in the continual gas flow, and the acceleration of a spherical particle by the gas flow can be expressed by the following equation when the interaction between the particles and gravity is ignored 6: pp pp Dp uuuu d C dt du = )( 4 3 Where up, dp, p represent particle velocity, diameter and density; CD is drag coefficient and expressed for a smooth spherical particle by eeD RaRaaC / 321 += and a1, a2, and a3 are constants, Re is the Reynolds number and defined by: /uudR ppe = and is the fluid dynamic viscosity and this equation can be practically applied to a Re 50000. Geometrical model. The jet flow region in cold spray process is made up of the internal flow of the nozzle and free jet flow region. Due to the use of nine holes nozzle, a three-dimensional model is built up in this study. Fig.1 shows the exit section diagram of the nine holes nozzle, and there are eight small holes with diameter of 1.67 mm uniformly distributed and a center hole with diameter of 2.6mm in the circular face with diameter of 6.4mm. The distance L (as shown in Fig.1) between the small hole and center hole is 2.25mm, the total area of the nine holes equals the exit area of the single hole with diameter of 5.4mm. Other dimensions of the Laval nozzle with nine holes are identical to the single hole nozzle, Fig.2 shows the section diagram of the Laval nozzle with single hole and computational domain, and its main dimensions are shown in table 1. Boundary conditions and solving method Gas inlet Outlet SoDAxis Wall Exit Divergent sectionConvergent section Substrate Fig.2 Section diagram of Laval nozzle with single hole and computational domain Inlet diameter(mm) 8 Convergent length(mm) 23 Divergent length(mm) 40 Throat diameter(mm) 2.7 Exit diameter(mm) 5.4 SoD(mm) 20 L Fig.1 Exit section diagram of the Laval nozzle with nine holes Table 1 Main dimensions of the Laval nozzle with single hole Advanced Materials Research Vols. 314-316 79 Gas inlet as shown in Fig.2 is selected for the pressure inlet boundary condition, and outlet is selected for the pressure outlet boundary condition which is atmosphere pressure and room temperature. And the air is selected as the accelerating gas. The standard k- turbulence model is utilized to disperse turbulence flow of gas, and standard wall functions are used to deal with the near wall region. Second-order upwind discretization scheme is used for governing equations. The computation of discrete phase follows the continuous phase flow field. Results and discussion Effect of SoD on particle velocity. The impact velocities of Cu particles with diameter of 2m sprayed by the Laval nozzle with the single hole and the nine holes are shown in Fig.3 with different SoD when spraying pressure P is 2.5MPa and spraying temperature T is 700K. It is seen clearly that the particle velocities obtained by the Laval nozzle with nine holes is higher than that of by the Laval nozzle with the single hole in the same simulation conditions. And the smaller the SoD, the higher the particle velocity may be obtained by the Laval nozzle with nine holes. It is also seen that the optimum SoD is 40mm when the Laval nozzle with single hole operates at P=2.5MPa and T=700K. 400 500 600 700 800 10 20 30 40 50 Pa rti cle ve loc ity (m /s) SoD (mm) Single hole Nine holes 300 400 500 600 700 800 0 5 10 15 Pa rti cle ve loc ity (m /s) Particle diameter (m) Single hole Nine holes Fig.3 Effect of SoD on particle velocity Fig.4 Effect of particle diameter on particle velocity When using the Laval nozzle with single hole, a series of compress waves are produced by the supersonic gas flow due to sharp compression before the substrate. And the shock wave will occur when the compression waves stacking with each other. Supersonic gas flow becomes subsonic gas flow when it goes through the shock wave, and the pressure, density, temperature of the gas flow rises sharply, while Mach number drops rapidly. The particle velocity decreases continuously owing to shock waves effect. The intensity of shock wave before the substrate also increases consequently with the decreasing of SoD, so does the influence on particle velocity. The gas flow tends towards stability, and so is the particle velocity when using the Laval nozzle with nine holes. Effect of particle diameter on particle velocity. Fig. 4 shows the effect of particle diameter on particle velocity when the Cu particles pass through the Laval gun to the substrate at the simulation conditions of SoD=40mm, P=2.5MPa and T=700K. It is seen clearly that the higher particle velocity may be obtained with the smaller particle using different Laval nozzle, while the particle velocity obtained by the Laval nozzle with nine holes is higher than that of the Laval nozzle with single hole at the same conditions. The particle velocity decreases rapidly by the effect of shock wave before the substrate because the small particle has much low mass, low inertia and influenced by the gas easily. While using the Laval nozzle with nine holes, particle velocity has a little change as the intensity of shock wave is diminished. The greater particle has higher weight, higher inertia and can not be accelerated easily by the gas, so the variation of the particle velocity is not apparent by the effect of shock wave before the substrate. Therefore the Laval nozzle with nine holes is appropriate for the small particles. Effect of pressure on particle velocity. Fig. 5 shows the effect of pressure on particle velocity when the Cu particles pass through the Laval gun with nine hole to the substrate at the simulation conditions of SoD=40mm, T=700K and the diameter of the Cu particle is 2m. The distance x as shown in Fig.5 80 Advanced Manufacturing Technology is from nozzle inlet to the substrate. It is seen clearly that the particle velocity has a little change and tends towards stability between the exit of nozzle and the substrate. With the increment of spray pressure, the particle velocity also has little change inside of the nozzle and small increase outside of the nozzle. Therefore there is little effect of the pressure on particle velocity. 0 100 200 300 400 500 600 700 800 900 0 0.02 0.04 0.06 0.08 0.1 0.12 Pa rti cle ve loc ity (m /s) x (m) 2.5 MPa 2.0 MPa 1.5 MPa 0 100 200 300 400 500 600 700 800 900 0 0.02 0.04 0.06 0.08 0.1 0.12 Pa rti cle ve loc ity (m /s) x (m) 700K 500K 300K Fig.5 Effect of pressure on particle velocity Fig.6 Effect of temperature on particle velocity Effect of temperature on particle velocity. Fig. 6 shows the effect of temperature on particle velocity when the Cu particles pass through the Laval gun with nine hole to the substrate at the simulation conditions of SoD=40mm, P=2.5 MPa and the diameter of the Cu particle is 2m. It is seen clearly that the effect of the spray temperature on particle velocity is large, and the higher the temperature, the higher the particle velocity. Furthermore, the massive plastic deformation occurs easier in both the incident particles and the substrate with the higher temperature. Conclusions (1) The particle velocity obtained by the Laval nozzle with nine holes is higher than that with the single hole at the same standoff distance, and the smaller the standoff distance, the higher the particle velocity may be obtained by the Laval nozzle with nine holes. (2) The higher particle velocity may be obtained with smaller particles using the Laval nozzle with nine holes at the same conditions. (3) The higher the spraying pressure and temperature may make the particle spraying with greater velocity using the Laval nozzle with nine holes. References 1 J. Pattison, S. Celotto, A. Khan. Surface & Coating Technology, Vol. 202 (2008), p. 1443-1454. 2 A. P. Alkhimov, S. V. Klinkov, et al. Journal of Applied Mechanics Technical Physics, Vol. 38, No. 2 (1997), p. 324-330. 3 D. L. Gilmore, R. C. Dykhuizen, et al. Journal of Thermal Spray Technology, Vol. 8, No. 4 (1999), p. 576-582. 4 R. C. Dykhuizen, M. F. Smith. Journal of Thermal Spray Technology, Vol. 7, No. 2 (1998), p. 205-212. 5 Hidemasa Takana, Kazuhiro Ogawa, Tetsuo Shoji. Powder Technology, Vol. 185 (2008), p. 116-123. 6 Wen-Ya Li, Hanlin Liao, G. Douchy. Materials and Design, Vol. 28 (2007), p. 2129-2137. Advanced Materials Research Vols. 314-316 81 Advanced Manufacturing Technology doi:10.4028/ Simulation of the Effect of Process Parameters on Particle Velocity in Cold Spray Using Laval Nozzle with Nine Holes doi:10.4028/