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外文原文 Computer-aided design of floating head heat exchanger based on UG software 1 introduction The EDS of Unigraphics (UG) software is currently the worlds most advanced integrated CAD/CAM/CAE of high-end software, widely used in aerospace, automobile, shipbuilding, general machinery and consumer electronics and other industrial fields.UG software is nowadays many of the worlds leading industrial product designer and manufacturer for concept design, industrial design, mechanical structure design and engineering simulation, digital manufacture technology .In China, the UG software has with Pro/E software to become the most popular with the users and the general acceptance of the three-dimensional parametric design software, for the popularization and improvement of Chinas manufacturing CAD technology has played a positive and significant effect .But in the current domestic users, most designers only use CAD and CAM module of UG software, the CAE module is rusty, and domestic information about UG and books to introduce CAE are few.In the developing of computer and CAD technology in modern times, the finite element analysis method will get more and more widely in engineering design and analysis, finite element analysis software and the integrated application of CAD system is to make the design level happen a qualitative leap, it can increase the reliability of the products and engineering, many conventional calculation doesnt give a analysis of the data, before the product manufacturing or engineering construction found potential problems in advance. 2main components of floating head heat exchanger CAD 2.1 parts modeling UG solid Modeling module (Modeling) USES the compound Modeling technology, the parameter design and characteristics of geometric design method combining Modeling.Mainly has the entity modeling, wire frame modeling, free-form surface modeling, etc. Three [4].Specific use what kind of modeling method, according to the characteristics of the object, we usually use mainly entity modeling.In entity parts model, can use basic voxel to establish a simple entity, can also be based on the curve to establish various scanning, sketches the stretching, rotating entity, can also use the system to provide features to create a variety of body.For a component model, although there is no a fixed sequence modeling and modeling methods, but still have certain rules to follow.Generally should be according to the structure characteristics of the components, to set up a basic voxel or scanning features, and then gradually create parts of holes, slotting, cavity, convex sets, convex pad and user defined features, finally to create roundingoff, chamfering, thread, pruning and arrays.According to the basic principle of floating head of floating-head type heat exchanger tube plate, saddle, tube box, shell and tube bundle main components such as 3 d modelling, model is intuitive, as shown in figure 1-5. 2.2 parts and componentsUG assembly module (Assemblies) using a pointer assembly parts rather than copy parts to realize virtual assembly [5], can reduce the memory requirements of assembly, check the assembly model in time if there is a design size of interference, the smooth progress of the actual assembly model for the future provide a reliable guarantee.Assembly information can be easily caused by the draw assembly drawings, and can quickly generate assembly diagram, save map assembly drawing and parts of time and cost.When change of assembly of parts, assembly will be automatically updated.Figure 6 to use the corresponding matching relationship of floating head heat exchanger assembly drawing, and transparent way outside shell shows the internal form of floating head heat exchanger assembly relation, the whole body of the heat exchanger is more intuitive. 2.3 to generate two-dimensional engineering graphics UG engineering drawing module (Drafting) can be easily with the entity model coordinated two-dimensional engineering graphics.When the entity model changes, the size of the engineering drawing sync automatically updates, reduce model change time needed for two-dimensional chart updates, fundamentally put an end to the traditional size contradictions in the design of two-dimensional engineering graphics, throw line, such as common errors, so as to ensure the correct of two-dimensional engineering graphics.Based on the floating head heat exchanger tube plate, for example by adding a master model view, projection views and local amplification figure views such as establishing two-dimensional engineering graphics, figure 7 is according to our country perfect tube plate drawing standards to modify the default drawing parameters of two-dimensional engineering graphics. 3 CAE implementation of floating head heat exchanger CAE analysis module of UG (Scenario) using the worlds most advanced calculator, such as the MSC/NASTRAN, MSC/PATRAN and MDI/were ADAMS, MOLDFLOW, etc.UG to the first-class software are not simply integration, but "implant" to it, do the consistency of the user interface, and according to the need to expand the corresponding function. 3.1 the installation process of floating head heat exchanger and the medium flow simulation Motion simulation is the main part of UG/CAE to, it can be on any 2 d or 3 d institutions complex kinematics simulation analysis, dynamic analysis and design.Through the above of floating head heat exchanger of the three-dimensional entity model is set up, using UG Scenario For the function of the Motion to the three-dimensional solid model of floating head heat exchanger need movement components are given in the kinematics characteristic of a certain to set up certain connections between the parts, thus the Motion of floating head heat exchanger is established the simulation model, and output the corresponding animation.The entire model are verified by simulation movement assembly and the rationality of the design of motion mechanism.The floating head heat exchanger structure and installation process more intuitive, more image, vivid internal medium flow. 3.2 the finite element analysis of the saddle The Scenario of UG for Structures is an integrated CAE tools.When concrete analysis part structure, the module will automatically with the parts of the structure of the network partitioning, boundary constraint and load condition changes correspondingly change, which the new results are obtained.So repeatedly, can be more easily scheme analysis, choose the optimal solution.Upon confirmation of scheme, digital model of CAD module will automatically change to get the best design model.In the floating head heat exchanger, saddle is used to support the horizontal heat exchanger [6], the design requirements and the saddle should have sufficient strength and resistance to deformation ability.This paper simulated the saddle by heat exchanger of the effect of gravity stress, the stress is displayed through the clouds, the size of the force function and is accompanied by the saddle and the deformation. 3.2.1 import master model and set the parameters Import figure 2 saddle as the main model, into the structure analysis module.Saddle material is Q235A, elastic modulus E = 220 x 109 pa, poissons ratio u = 0.3, density of rho = 7.85 x 10-6 kg/mm3.Material properties as shown in the table 1. 3.2.2 applied load and constraints Pressure on the saddle here only consider heat exchanger, the heat exchanger and the total weight of the fluid W / 2 = 50000 n, with the circular arc of the bearing load ACTS on the saddle surface, as shown in figure 8, since the role of the saddle by anchor bolt, with anchor bolt is fixed on the ground.Symmetry constraint in the bolt hole, at the hem of vertical displacement constraints.As shown in figure 9. 3.2.3The finite element grid was divided Meshing was done for the whole model, the use of smart grid, such a finer division of grid, the results of the analysis more accurate, this paper choose the UG software bring UGVM network generator four nodes tetrahedron three-dimensional grid, mesh of finite element model is shown in figure 10. 3.2.4 solving and result output Prior to calculation, the finite element model for a check to see whether setting error, the system will provide a inspection report, can be set according to the report of some unreasonable, modified the calculation is reasonable, no error message. Output saddle seat move diagram (see figure 11) and stress diagram (see figure 12), figure 11 shows the saddle on the Z axis direction due to the pressure of the heat exchanger and the displacement in the Z axis.Can consider when processing between two straight floor with two support bar, to strengthen the resistance to deformation ability of the saddle.Figure 12 shows the saddle load cases, the two straight floor produces large stress, and on the floor with spot welding with gasket stress concentration.Other local stress distribution is more homogeneous.Therefore, we in the machining process of the saddle to improve the quality of the weld on select material is available in the separation of high strength material. 4 conclusion Create of floating head heat exchanger using UG 3 d model of the parts and image, vivid, intuitive reflect the structure of floating head heat exchanger;Using UG to the strength analysis of some parts effectively improves the reliability of these parts;Production of three-dimensional dynamic simulation for engineering and technical personnel to master the structure and working principle of floating head heat exchanger;For producers and installers save analysis time, improve the production efficiency at the same time. Visible, along with the development of the computer aided technology and computer network technology, the heat exchanger will realize from the design, manufacturing to sales and maintenance of computer and information technology.With the aid of the powerful features of the computer aided technology, can realize the optimal design of heat exchanger, greatly improve the reliability of heat exchanger, at the same time with the aid of computer network technology, can realize resource sharing in the whole industry, improve the efficiency of heat exchanger design, manufacture, save a lot of production cost and create greater economic benefits for the enterprise. 譯文 基于UG軟件的浮頭式換熱器計算機輔助設計 1 前言 美國EDS公司推出的Unigraphics(簡稱UG)軟件是當前世界上最先進的集成CAD/CAM/CAE的高端軟件，廣泛應用于航空航天、汽車、造船、通用機械和消費電子產(chǎn)品等工業(yè)領域。UG軟件被當今許多世界領先的工業(yè)產(chǎn)品設計商與制造商用來從事概念設計、工業(yè)設計、機械結構設計以及工程仿真、數(shù)字化制造等各個技術領域。在中國，ＵＧ軟件已經(jīng)和Pro/Ｅ等軟件一起成為最受用戶歡迎和普遍接受的三維參數(shù)化設計軟件，為中國制造業(yè)CAD技術的普及和提高起到了積極顯著的作用。但就目前國內用戶而言，大多數(shù)設計者只使用UG軟件中的CAD和CAM模塊，對CAE模塊比較生疏，而國內關于ＵＧ的資料與書籍對CAE也很少有介紹。在計算機和CAD技術大力發(fā)展的當今時代，有限元分析方法在工程設計和分析中將得到越來越廣泛的重視，有限元分析軟件與CAD系統(tǒng)的集成應用使設計水平發(fā)生了質的飛躍，它能增加產(chǎn)品和工程的可靠性，得到許多常規(guī)計算無法得出的分析數(shù)據(jù)，在產(chǎn)品制造或工程施工前預先發(fā)現(xiàn)潛在的問題。 2 浮頭式換熱器的主要零部件CAD實現(xiàn) 2.1 零件建模 UG實體建模模塊(Modeling)采用復合建模技術，將參數(shù)設計和特征幾何設計等方法結合起來建模。主要有實體建模、線框建模、自由曲面建模等3種[4]。具體用哪一種建模方法，要依據(jù)對象的特點而定，我們通常用到的主要是實體建模。在建立實體零件模型時，既可以用基本體素建立簡單的實體，也可以通過對曲線、草圖的拉伸、旋轉建立各種掃描實體，還可以用系統(tǒng)提供的特征創(chuàng)建各種特征體。對于一個零件模型，雖然沒有一種固定的建模順序和建模方法，但是還是有一定規(guī)律可循的。一般應根據(jù)零部件的結構特點，先建立一個基本體素或掃描特征，再逐步創(chuàng)建零件的孔、鍵槽、型腔、凸臺、凸墊及用戶定義等特征，最后創(chuàng)建倒圓、倒角、螺紋、修剪和陣列等特征。按照上述基本原則對浮頭式換熱器浮頭管板、鞍座、管箱、筒體及管束等主要零部件進行三維造型，模型真實直觀，如圖1-5所示。 2.2零部件裝配 UG裝配模塊(Assemblies)使用指針裝配零件而不是拷貝零件實現(xiàn)虛擬裝配[5]，可以使裝配的內存需求減少，及時檢查裝配模型是否存在設計尺寸干涉，為將來實際裝配模型的順利進行提供可靠保證。由此所產(chǎn)生的裝配信息可以方便地繪制裝配圖，并能快速生成裝配分解圖，節(jié)省繪制裝配圖和零件圖的時間和成本。當組成裝配的零件有所改變時，裝配會自動更新。圖6為運用相應的配對關系建立的浮頭式換熱器裝配圖，并以外殼體透明的方式展示了浮頭式換熱器內部組建的裝配關系，使換熱器的整體機構更加真實直觀。 2.3二維工程圖生成 UG工程制圖模塊(Drafting)可以方便地得到與實體模型協(xié)調一致的二維工程圖。當實體模型改變時，工程圖尺寸會同步自動更新，減少因模型改變二維圖更新所需時間，從根本上杜絕傳統(tǒng)的二維工程圖設計中尺寸矛盾、丟線等常見錯誤，從而保證二維工程圖的正確無誤。本文以浮頭式換熱器管板為例通過添加主模型視圖，投影視圖及局域放大圖等視圖建立二維工程圖，圖7為按照我國制圖標準修改缺省圖紙參數(shù)完善的管板的二維工程圖。 3 浮頭式換熱器的CAE實現(xiàn) UG的CAE分析模塊(Scenario)采用世界上最先進的計算器，如MSC/NASTRAN、MSC/PATRAN、MDI/ADAMS、MOLDFLOW等。UG對這些一流的軟件并不是簡單地集成，而是“植入”到其中，做到用戶界面的一致性，并根據(jù)需要擴充相應的功能。 3.1浮頭式換熱器的安裝過程及介質流動仿真 運動仿真是UG/CAE模塊中的主要部分，它能對任何二維或三維機構進行復雜的運動學分析、動力分析和設計仿真。通過以上建立的浮頭式換熱器的三維實體模型，利用UG的Scenario For Motion的功能給浮頭式換熱器的三維實體模型中的需要運動的部件賦予一定的運動學特性，再在各個部件之間設立一定的連接關系，從而建立浮頭式換熱器的運動仿真模型，并輸出相應的動畫。通過運動仿真檢驗了整個模型裝配及運動機構設計的合理性。使浮頭式換熱器結構及安裝過程更直觀、內部介質流動更加形象、逼真。 3.2鞍座的有限元分析 UG的Scenario for Structures是一個集成的CAE工具。在具體分析零件結構時，該模塊會自動隨零件結構的網(wǎng)絡劃分、邊界約束、載荷工況發(fā)生的變化作相應的變化，從而得出新的結果。這樣反復多次，可很方便地進行多方案的分析，從中選出最優(yōu)的方案。方案一經(jīng)確認，CAD模塊的數(shù)字模型也會自動地改變，從而得到最佳的設計模型。在浮頭式換熱器中，鞍座是用來支撐臥式換熱器的[6]，設計要求鞍座要有足夠的強度和抗變形能力。本文模擬鞍座受換熱器的重力的作用而產(chǎn)生的應力，該應力的大小是通過云圖顯示出來的，并伴隨有鞍座受力作用而產(chǎn)生的變形。 3.2.1 導入主模型并設置參數(shù) 導入圖2鞍座作為主模型，進入結構分析模塊。鞍座材料為Q235A，彈性模量E=220109Pa，泊松比μ=0.3，密度ρ=7.8510-6 kg/mm3。材料特性詳見表1。 3.2.2 施加載荷與約束 在這里只考慮換熱器對鞍座的壓力，即換熱器與流體的總重量W/2=50000N，以軸承載荷作用于鞍座的圓弧面上，如圖8所示，因為鞍座受地腳螺栓的作用，以地腳螺栓固定在地面上。在螺栓孔處產(chǎn)生對稱約束，在底邊上產(chǎn)生豎直方向的位移約束。如圖9所示。 3.2.3 劃分有限元網(wǎng)格 對整個模型進行網(wǎng)格劃分，使用智能網(wǎng)格劃分，這樣劃分出來的網(wǎng)格更細，分析的結果更精確，本文選擇UG軟件自帶的UGVM網(wǎng)絡生成器生成四節(jié)點四面體三維立體網(wǎng)格，劃分網(wǎng)格后的有限元模型如圖10所示。 3.2.4 求解及結果輸出 在進行計算之前，對有限元模型進行一次檢查是否設置錯誤，系統(tǒng)會提供一份檢查報告，可以根據(jù)報告對一些不合理的設置進行修改，本次計算合理，無錯誤信息。 輸出鞍座位移圖（詳見圖11）和應力圖（詳見圖12），圖11說明鞍座在Z軸方向上因受換熱器的壓力而產(chǎn)生的在Z軸方向上的位移。在加工時可以考慮在兩直肋板間加上兩根支撐桿，以加強鞍座的抗變形能力。圖12說明鞍座負重情況下，在兩直肋板產(chǎn)生較大應力，且在肋板與墊片的焊接處有應力集中情況發(fā)生。其它地方應力分布較均勻。故此，我們在鞍座的加工過程中要提高焊縫的質量，選材上可在這部分選強度高的材料。 4 結論 用UG創(chuàng)建的浮頭式換熱器零部件的三維模型，形象、逼真，非常直觀的反映了浮頭式換熱器構造；運用UG對部分零部件進行的強度分析有效地的提高了這些零部件可靠性；制作的三維動態(tài)模擬能夠方便廣大工程技術人員掌握浮頭式換熱器的結構與工作原理；為生產(chǎn)者以及安裝者節(jié)省了分析時間，同時提高了生產(chǎn)效率。 可見，隨著計算機輔助技術和計算機網(wǎng)絡技術的發(fā)展，換熱器將實現(xiàn)從設計、制造到銷售、維護的計算計化與信息化。借助計算機輔助技術的強大功能，完全可以實現(xiàn)換熱器的最優(yōu)化設計，大大提高換熱器的可靠性，同時借助計算機網(wǎng)絡技術，可以實現(xiàn)在全行業(yè)內的資源共享，提高換熱器設計、制造的效率，節(jié)約大量的生產(chǎn)成本，為企業(yè)創(chuàng)造更大的經(jīng)濟效益。