| 李会荣1， 潘俊兵1， 任景涛1,2.基于有限元的铝箔涂布钢辊结构优化[J].轻工机械,2025,43(5):82-86 |
| 基于有限元的铝箔涂布钢辊结构优化 |
| Structural Optimization of Aluminum Foil Coating Steel Rollers Based on Finite Element Analysis |
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| DOI：10.3969/j.issn.1005 2895.2025.05.011 |
| 中文关键词: 涂布钢辊 铝箔 支撑辊套拓扑构型 支撑结构 有限元分析 |
| 英文关键词:coating steel roller aluminum foil support roller sleeve topological configuration support structure FEA（Finite Element Analysis） |
| 基金项目:陕西省教育厅科研项目（24JR020）；陕西省教育厅科研项目（24JK0322）；陕西国防工业职业技术学院 2025 年度科研重点项目（Gfy25 03）；陕西国防工业职业技术学院2024年度科研项目（Pt24 05）。 |
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| 中文摘要: |
| 针对铝箔涂布钢辊轴端断裂失效难题，课题组通过高精度有限元分析与拓扑优化设计，提出创新性支撑结构解决方案。基于UG NX 12.0与Hypermesh建立参数化模型（网格划分最小四面体网格边长为1 mm），结合ANSYS Workbench仿真揭示了原结构辊轴端（轴承安装面过渡区）存在应力集中现象，最大应力为366.0 MPa，超出了45#钢屈服强度，与工厂实际失效位置高度吻合；课题组突破传统“增厚辊套”的思路，创新设计了单、双支撑辊套拓扑构型，在辊套厚度减薄44%（辊套厚度从18 mm减小到10 mm）的前提下，单、双支撑辊套钢辊最大应力分别降至18.4 MPa与62.4 MPa。经18个月工厂实验验证结果表明：结构优化后的钢辊寿命为优化前的6倍以上，年更换频次由4.0次降至0.7次，节约单生产线年维护成本超64万元。该研究对高张力铝箔涂布装备的轻量化、可靠性研究具有参考意义。 |
| 英文摘要: |
| Addressing the fracture failure challenge at the shaft end of aluminum foil coating steel rollers, an innovative support structure solution was proposed through high precision finite element analysis (FEA) and topological optimization design. Parametric models (minimum mesh size 1 mm) were established using UG NX 120 and Hypermesh. ANSYS Workbench simulation showed that there was stress concentration at the end of the original structure roller shaft (transition zone of bearing installation surface), with a maximum stress of 366.0 MPa, exceeding the yield strength of 45# steel and highly consistent with the actual failure location of the factory.Breaking away from the conventional "thicken the roller sleeve" approach, the single support and double support topological configurations for the roller sleeve were innovatively designed. Under the premise of reducing the thickness of the roller sleeve from 18 mm to 10 mm and thinning the roller sleeve thickness by 44%, the maximum stress of single support and double support roller sleeves decreased to 18.4 MPa and 62.4 MPa, respectively. Validated through an 18 month industrial trial, the results indicate that the optimized steel roller demonstrated a service life increase exceeding 6 fold，and the annual replacement frequency decreased from 4.0 times to 0.7 times, achieving annual maintenance cost savings of over 640 000 yuan per production line.This study has reference significance for research on the lightweight design and high reliability of high tension aluminum foil coating equipment. |
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