CAE技术在车灯热板焊接中的应用
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摘要
热板焊接是常用的塑料焊接技术之一,汽车尾灯的密封使用该技术完成。因在车灯的设计前期无法对焊接筋的结构做出准确评估,时常会有假焊、虚焊的现象发生,最终导致焊接品质不满足要求。本文基于CAE技术,根据测得的焊接压力与给定的焊接方向,进行热板焊接的静力分析,预测出了焊接筋在加压过程中的易偏移区域。针对该区域进行加筋优化,并利用检具测量了优化前后的面差结果,结果表明面差最大区域与模拟最大偏移区域相符,证明了模拟的可靠性。加筋优化后,最大面差数值由-0.87 mm变为-0.61 mm,证明了加筋能有效改善因焊接偏移引起的面差问题。
Hot plate welding is one of the common technology used in plastic welding. The assembling of automotive lamp is achieved by this technology. As in the pre-design phase, the design of welding rib could not be evaluated accurately, spurious welding happens sometimes, which can cause the quality of welding not to meet the requirement. Based on CAE technology, according to the measured welding pressure and given welding direction, the static analysis is carried out for the hot plate welding, and the unstable areas are forecasted. The structure is optimized for these areas. Flush are measured by checking fixture for two different structure. Results show that the area with maximum flush is the same with the area with maximum displacement pointed by simulation. These results can verify the accuracy of simulation. After adding ribs, the maximum flush is changed from-0.87 mm to-0.61 mm, test results show that the flush problem caused by welding could be improved effectively by adding ribs.
Hot plate welding is one of the common technology used in plastic welding. The assembling of automotive lamp is achieved by this technology. As in the pre-design phase, the design of welding rib could not be evaluated accurately, spurious welding happens sometimes, which can cause the quality of welding not to meet the requirement. Based on CAE technology, according to the measured welding pressure and given welding direction, the static analysis is carried out for the hot plate welding, and the unstable areas are forecasted. The structure is optimized for these areas. Flush are measured by checking fixture for two different structure. Results show that the area with maximum flush is the same with the area with maximum displacement pointed by simulation. These results can verify the accuracy of simulation. After adding ribs, the maximum flush is changed from-0.87 mm to-0.61 mm, test results show that the flush problem caused by welding could be improved effectively by adding ribs.
引文
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[2]陶永亮.汽车灯罩与灯体装配连接方式[J].汽车工程师, 2012(11):55-58.
[3]机械工程材料性能数据手册编委会.机械工程材料性能数据手册[M].北京:机械工业出版社, 1995:221-222.
[4]黄志新. ANSYS Workbench 16.0超级学习手册[M].北京:人民邮电出版社, 2016:147-149.
[5]余乐鸿,朱庆棠.热板焊接及其在车灯行业的应用[J].汽车电器, 1995(6):11-13.