微型汽车内外饰产品设计制造技术基础研究
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摘要
随着汽车行业的不断发展,大部分微型汽车内外饰产品都是选用塑料材料通过注塑成型制造加工的。在汽车内外饰产品开发的过程中,材料的选用、零件的结构设计、注塑成型生产的工艺条件等因素不仅直接关系到内外饰产品的使用性能,而且会影响到整车的质量和成本。因此,研究汽车用塑料材料、内外饰产品的结构设计和注塑成型工艺参数对内外饰产品性能的影响规律,进而提高内外饰产品的质量和降低开发成本是所有汽车生产厂家亟待解决的主要问题之一,也是一项具有重要科学价值和实践意义的课题。本文旨在通过材料分析、有限元仿真模拟辅以试验验证的方法,探讨材料属性和注塑成型工艺条件对微型汽车内外饰产品性能的影响规律；利用DOE实验方法、智能寻优算法,建立内外饰产品成型缺陷预测模型和工艺参数寻优方法,并基于该方法针对目标产品进行注塑成型缺陷最小化的工艺参数寻优；基于知识工程建立汽车内外饰产品设计辅助专家系统。研究成果可为微型汽车内外饰产品开发提供理论依据和实践指导。本文的主要研究内容如下：
(1)基于塑料材料学理论、利用材料检测技术,建立实验方案研究微型车用改性PP材料主要配方成分及其含量对复合材料性能的影响规律。
(2)基于有限元仿真模拟,建立微型汽车内外饰产品有限元分析模型并完成目标产品模型的刚度强度分析和注塑成型性分析；根据内外饰产品的实际边界条件搭建台架试验台,并完成相应的物理实验对有限元仿真模拟予以验证；系统的研究微型汽车用改性PP的关键材料属性对内外饰产品的机械性能和成型性能的影响规律；进而建立微型汽车用改性PP类材料配方体系,并对其进行零件试制验证。
(3)基于注塑成型有限元仿真模拟,建立典型汽车内饰产品注塑成型分析有限元模型,并完成相应的注塑成型模拟实验分析,进而系统的研究不同注塑成型阶段(注射、保压、冷却)下不同的工艺参数(时间、温度、压力)对目标产品的注塑成型过程和成型质量的影响规律。
(4)基于实验方法和智能算法,建立内外饰产品成型缺陷预测模型和工艺参数寻优方法；基于加强筋背面缩痕缺陷产生的机理,提出加强筋缩痕理论分析模型,基于DOE实验方法建立实验方案,研究目标因子及其之间的交互作用对加强筋理论分析模型产生缩痕缺陷的影响规律,并建立因子与响应(因子与缩痕)之间的数学关系模型；利用智能寻优算法对加强筋模型进行缩痕最小化的因子寻优,并对寻优结果进行实验验证；将所建立的成型缺陷预测和工艺优化方法应用于实际内外饰产品的缺陷预测和工艺参数优化设计。
(5)基于微型汽车内外饰产品开发流程,对开发过程中的材料选择、结构设计等关键方面的相关知识进行归纳提炼、编码设计、程序化转化,使之成为系统可读性数据(规则知识和事例知识)；基于知识工程,对微型汽车内外饰产品材料和结构设计的相关知识进行分类、表示,并建立系统的知识数据库；利用知识库和SQL结构化查询语言完成系统的物理模型建立、总体框架及其子模块设计、系统计算机实现方式及其安全管理；利用网页编程工具完成系统的界面设计；从而建立微型汽车内外饰产品材料工艺数据库和结构设计辅助系统帮助设计人员进行内外饰产品的材料选择和零件结构设计。
With the development of automotive industry,the majority of interior and exterior trim of commercial vehicle are made of plastic material by using injection molding. In the process of automotive interior and exterior product development, material selection, the product structure design, injection molding production process conditions and other factors not only directly related to the functional performance of automotive interior and exterior, but also will affect the vehicle quality and the cost of vehicle development. Therefore, study on the influence of plastic material properties, product structure design and molding process parameters on automotive interior and exterior product performance have become hot topics with high scientific and practical significances. The aims of this dissertation are to research the influence of plastic material properties and molding process parameters on automotive interior and exterior product performance, and to establish a automotive interior and exterior product design supplementary system. The research results can provide a theoretical basis and practical guidance for the development of automotive interior and exterior. The main contents of this dissertation are listed as follows..
(1) Based on testing of materials, the influences of ingredients and content of PP on properties of composite materials were analysed.
(2) FE model and bench test bench were established by using an analytical method as well as a nano-indentation test. The influences of material properties on mechanical properties and forming property of products were analysed by finite element simulation experiment of structural strength/stiffness analysis and forming analysis. Also, material formula system were established and validated.
(3) FE model of an automotive interior product was established and the simulation analysis were carried out in the Moldflow software. The influences of process parameters (time, tempreture, pressure) under different injeciton process on injection molding process and forming quality were analysed.
(4) A simplified analysis model was designed under the mechanism of sink-mark defects generating. By using DOE method, influences of factors and interreaction of each other on sink-mark of the model were researched, and mathematical model of the relationship between factors and response (factors and sink-mark) was established. Sink-mark defect of the model was minimizing in injection molding through response surface regression modeling and intelligent algorithm, the results have been validated. Also, this method was applied to process design of actual product.
(5) The related knowledge of material selection, structure design and other key aspects in the development process were summarized, code designed, and program transformed to become computer readable data. Physical model, overall and module design, computer realization and security management of the system were established by using knowledge base and structured query language. Material technology database and computer-aided system of automotive interior and exterior were established to help the designer to select materials and desing product structure.
(1)基于塑料材料学理论、利用材料检测技术,建立实验方案研究微型车用改性PP材料主要配方成分及其含量对复合材料性能的影响规律。
(2)基于有限元仿真模拟,建立微型汽车内外饰产品有限元分析模型并完成目标产品模型的刚度强度分析和注塑成型性分析；根据内外饰产品的实际边界条件搭建台架试验台,并完成相应的物理实验对有限元仿真模拟予以验证；系统的研究微型汽车用改性PP的关键材料属性对内外饰产品的机械性能和成型性能的影响规律；进而建立微型汽车用改性PP类材料配方体系,并对其进行零件试制验证。
(3)基于注塑成型有限元仿真模拟,建立典型汽车内饰产品注塑成型分析有限元模型,并完成相应的注塑成型模拟实验分析,进而系统的研究不同注塑成型阶段(注射、保压、冷却)下不同的工艺参数(时间、温度、压力)对目标产品的注塑成型过程和成型质量的影响规律。
(4)基于实验方法和智能算法,建立内外饰产品成型缺陷预测模型和工艺参数寻优方法；基于加强筋背面缩痕缺陷产生的机理,提出加强筋缩痕理论分析模型,基于DOE实验方法建立实验方案,研究目标因子及其之间的交互作用对加强筋理论分析模型产生缩痕缺陷的影响规律,并建立因子与响应(因子与缩痕)之间的数学关系模型；利用智能寻优算法对加强筋模型进行缩痕最小化的因子寻优,并对寻优结果进行实验验证；将所建立的成型缺陷预测和工艺优化方法应用于实际内外饰产品的缺陷预测和工艺参数优化设计。
(5)基于微型汽车内外饰产品开发流程,对开发过程中的材料选择、结构设计等关键方面的相关知识进行归纳提炼、编码设计、程序化转化,使之成为系统可读性数据(规则知识和事例知识)；基于知识工程,对微型汽车内外饰产品材料和结构设计的相关知识进行分类、表示,并建立系统的知识数据库；利用知识库和SQL结构化查询语言完成系统的物理模型建立、总体框架及其子模块设计、系统计算机实现方式及其安全管理；利用网页编程工具完成系统的界面设计；从而建立微型汽车内外饰产品材料工艺数据库和结构设计辅助系统帮助设计人员进行内外饰产品的材料选择和零件结构设计。
With the development of automotive industry,the majority of interior and exterior trim of commercial vehicle are made of plastic material by using injection molding. In the process of automotive interior and exterior product development, material selection, the product structure design, injection molding production process conditions and other factors not only directly related to the functional performance of automotive interior and exterior, but also will affect the vehicle quality and the cost of vehicle development. Therefore, study on the influence of plastic material properties, product structure design and molding process parameters on automotive interior and exterior product performance have become hot topics with high scientific and practical significances. The aims of this dissertation are to research the influence of plastic material properties and molding process parameters on automotive interior and exterior product performance, and to establish a automotive interior and exterior product design supplementary system. The research results can provide a theoretical basis and practical guidance for the development of automotive interior and exterior. The main contents of this dissertation are listed as follows..
(1) Based on testing of materials, the influences of ingredients and content of PP on properties of composite materials were analysed.
(2) FE model and bench test bench were established by using an analytical method as well as a nano-indentation test. The influences of material properties on mechanical properties and forming property of products were analysed by finite element simulation experiment of structural strength/stiffness analysis and forming analysis. Also, material formula system were established and validated.
(3) FE model of an automotive interior product was established and the simulation analysis were carried out in the Moldflow software. The influences of process parameters (time, tempreture, pressure) under different injeciton process on injection molding process and forming quality were analysed.
(4) A simplified analysis model was designed under the mechanism of sink-mark defects generating. By using DOE method, influences of factors and interreaction of each other on sink-mark of the model were researched, and mathematical model of the relationship between factors and response (factors and sink-mark) was established. Sink-mark defect of the model was minimizing in injection molding through response surface regression modeling and intelligent algorithm, the results have been validated. Also, this method was applied to process design of actual product.
(5) The related knowledge of material selection, structure design and other key aspects in the development process were summarized, code designed, and program transformed to become computer readable data. Physical model, overall and module design, computer realization and security management of the system were established by using knowledge base and structured query language. Material technology database and computer-aided system of automotive interior and exterior were established to help the designer to select materials and desing product structure.
引文
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