基于小弯曲半径的线材折弯设计与角度误差分析

Wire bending design and angle error analysis based on small bending radius

针对线材折弯工艺在线材直径较小且折弯长度较短的情况下,由于折弯半径过大无法满足折弯要求的现状,通过伺服控制技术提出一种基于小弯曲半径的线材折弯成形方法,建立了线材折弯过程的数学模型,推导出折弯刀进给量与折弯角度的关系。以此为基础设计了对小弯曲半径线材折弯的折弯机,并对折弯模块和折弯刀具做了详细的设计。以设计的折弯机为实验样机对直径为Φ0.5 mm的铜线进行折弯实验研究,将理论值与实际折弯角度进行对比,结合实验数据对线材折弯角度误差做了分析,得出线材折弯回弹是影响折弯角度的主要因素。最后通过对实验数据拟合的方法推导出折弯刀进给量与折弯角度的经验公式,并应用于折弯成形实验中,取得了明显的折弯补偿效果。

For the wire bending process,when the diameter of the wire was small and the bending length was short,the bending radius could not be satisfied due to the excessive bending radius,a wire bending forming method based on small bending radius was proposed by the servo control technology. Then,the mathematical model of the wire bending process was established,and the relationship between feeding amount and bending angle of the bending knife was derived. Based on this,a bending machine for wire with a small bending radius was designed,and the bending module and the bending knife were designed in detail. Furthermore,the bending experiment of the copper wire with diameter Φ0.5 mm was conducted by the designed bending machine as the experimental prototype,and the theoretical value was compared with the actual bending angle. Combining with the experimental data,the bending angle error of the wire was analyzed,and it is concluded that the wire bending springback is the main factor affecting the bending angle. Finally,the empirical formula of the feeding amount and bending angle for the bending knife was derived by fitting the experimental data,and it was applied to the bending experiment to obtain the obvious bending compensation effect.