目的 为满足某型机载产品振动试验的高量级试验要求,解决传统振动工装设计质量超重、动态传递特性不佳等问题,开展基于ANSYS Workbench 的振动工装拓扑优化设计、仿真分析与试验验证研究。方法 以铝合金2A12为材料,设计倒锥形初版工装模型,通过模态分析明确其动力学特性。基于模态分析结果,采用变密度法构建3种拓扑优化方案（第1阶模态频率最大化、第4阶模态频率最大化、质量最小化）,结合加工工艺与工程经验完成模型重构,通过谐响应分析、随机振动分析验证重构模型的动态特性与结构强度,最终通过实物振动试验验证重构模型的可行性。结果 重构后工装质量降至56.91 kg,满足60 kg以下质量要求,减重率达18.27%,Z方向1阶模态频率为1 688.7 Hz,满足工装设计要求。谐响应分析显示,其共振峰对应频率与Z向1阶模态频率基本一致。随机振动分析表明,Z向响应最大加速度及应力均满足结构强度要求。实物振动工装在正弦扫频试验中控制曲线稳定在1g,最大尖峰为1.216 8g,随机振动试验控制曲线RMS值为28.124 6g,表明动态传递特性良好。结论 该研究验证了拓扑优化方法在振动工装设计中的适用性与有效性,在保证结构刚度的前提下实现了工装轻量化设计,可有效缩短设计周期、降低试验成本,为同类振动工装的设计优化提供了切实可行的工程参考。
Abstract
The study aims to conduct a study on the topology optimization design, simulation analysis for the vibration fixtures based on ANSYS Workbench, and test verification of vibration fixtures, tomeet the high-level test requirements of an airborne product vibration test, and solve the problems such as overweight and poor dynamic transmission performance in traditional vibration fixture design. An inverted conical preliminary fixture model was designed using 2A12 aluminum alloy, and its dynamic characteristics were determined through modal analysis. On this basis, three topology optimization schemes were constructed by the variable density method (maximizing the first modal frequency, maximizing the fourth modal frequency, and minimizing mass). The model reconstruction was completed by combining the machining processes and engineering experience. The dynamic characteristics and structural strength of the reconstructed model were verified through harmonic response analysis and random vibration analysis. Finally, the feasibility of the reconstructed model was verified through physical vibration tests. The mass of the reconstructed fixture was reduced to 56.91 kg, which met the requirement of below 60 kg, and the weight reduction rate was 18.27%. The first modal frequency in the Z direction was 1 688.7 Hz, which satisfied the requirements for fixture design. Harmonic response analysis indicated that the resonance peak frequency was basically consistent with the first modal frequency in the Z direction. Random vibration analysis showed that the maximum response acceleration and stress in the Z direction met the structural strength requirements. In the physical test, the control curve of the sine sweep test was stable at 1g, and the maximum peak was 1.216 8g. For the random vibration test, the RMS value of the control curve was 28.124 6g, indicating that its dynamic transmission characteristics were good. This study verifies the applicability and effectiveness of the topology optimization method in vibration fixture design. The lightweight design of the fixture is realized, while ensuring structural stiffness, which can effectively shorten the design cycle and reduce the test costs. It provides a practical engineering reference for the design and optimization of similar vibration fixtures.
关键词
动力学分析 /
拓扑优化 /
模态分析 /
轻量化设计 /
振动工装 /
振动试验
Key words
dynamic analysis /
topological optimization /
modal analysis /
lightweight design /
vibration fixture /
vibration test
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