差厚拼焊板零件焊缝线偏移的控制方法
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摘要
基于差厚拼焊板成形时由于板料发生塑性变形从而不可避免地会出现焊缝线偏移现象,采取预先对坯料焊缝线进行调整优化的方式来缩小成形后焊缝线与设计焊缝线的偏差。先在压料面或填补的孔洞上延伸合并分离的焊缝线,然后将焊缝线离散成系列点后通过网格映射法建立设计焊缝线、坯料焊缝线及成形后焊缝线三者之间的位置映射关系,然后通过仿真计算获取成形后焊缝线与设计焊缝线各对应离散点之间的偏差,并依据偏差值对坯料焊缝线离散点进行相应的偏移,获得坯料理想的曲线焊缝。在此基础上对曲线焊缝直线化,并根据直线焊缝坯料的仿真计算结果对坯料焊缝进行适当的偏转和平移,从而缩小成形后焊缝线相对于设计焊缝线的偏差。冲压试验结果表明该方法是有效的,同时也揭示了成形后焊缝线相对于设计焊缝线有偏差主要是因为坯料选用了直线焊缝。
Deviations between the design weld lines and the formed weld lines were inevitable in the stamping processes of TWB with different thicknesses due to the plastic deformations, so a method to shrink the deviations by adjusting the weld lines on the blanks in advance was put forward. Firstly, design weld lines were transformed into a integrated curves by extending to the binder or the filled holes according to the process supplement surfaces, then the integrated ones were discretized into a series of points to establish the position relationship of each discrete point between the three of the designed weld lines, the blank lines and the formed lines, then the deviations of each corresponding points between the formed weld line and the design lines were calculated through stamping simulations, the ideal weld curve on blank could be acquired through adjusting the blank discrete point according to the deviations calculated before. Based on these, the weld curves of blanks would be transformed into a straight line, which would be rotated and moved properly according to stamping simulation results to further shrink the deviations between the formed weld line and the design lines. The stamping test results show that the method is effective and reveals the main sources of deviations are coming from straight weld lines of the blank.
Deviations between the design weld lines and the formed weld lines were inevitable in the stamping processes of TWB with different thicknesses due to the plastic deformations, so a method to shrink the deviations by adjusting the weld lines on the blanks in advance was put forward. Firstly, design weld lines were transformed into a integrated curves by extending to the binder or the filled holes according to the process supplement surfaces, then the integrated ones were discretized into a series of points to establish the position relationship of each discrete point between the three of the designed weld lines, the blank lines and the formed lines, then the deviations of each corresponding points between the formed weld line and the design lines were calculated through stamping simulations, the ideal weld curve on blank could be acquired through adjusting the blank discrete point according to the deviations calculated before. Based on these, the weld curves of blanks would be transformed into a straight line, which would be rotated and moved properly according to stamping simulation results to further shrink the deviations between the formed weld line and the design lines. The stamping test results show that the method is effective and reveals the main sources of deviations are coming from straight weld lines of the blank.
引文
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[8] 朱元右, 姜银方, 杨继昌,等. 拼焊板冲压成形中的焊缝移动分析[J]. 中国机械工程, 2006, 17(15):1618-1622.ZHU Yuanyou, JIANG Yinfang, YANG Jichang, et al. Analysis of Weld-line Movement in Tailor-welded Blanks' formation[J]. China Mechanical Engineering, 2006, 17(15):1618-1622.
[9] HE S. Formability Enhancement for Tailor-welded Blanks Using Blank Holding Force Control[J]. Journal of Manufactu-ring Science & Engineering, 2003, 125(3):461-467.
[10] TANG B T, ZHAO Z, WANG Y. One-step FEM-based Evaluation of Weld Line Movement and Development of Blank in Sheet Metal Stamping with Tailor-welded Blanks[J]. International Journal of Advanced Manufacturing Technology, 2007, 35(3/4):268-279.
[11] KU T W, KANG B S, PARK H J. Tailored Blank Design and Prediction of Weld Line Movement Using the Backward Tracing Scheme of Finite Element Method[J]. International Journal of Advanced Manufacturing Technology, 2005, 25(1/2):17-25.
[12] 龚志辉, 李光耀, 钟志华. 基于网格映射法实现修边线的精确计算[J]. 湖南大学学报(自然科学版), 2008, 35(12): 18-22.GONG Zhihui, LI Guangyao, ZHONG Zhihua. Realization of Accurate Calculation for Trimming Line Based on Grid Mapping[J]. Journal of Hunan University(Natural Sciences), 2008, 35(12): 18-22.
[2] 李玉强, 王勇, 田华,等. 车门不等厚拼焊板冲压成形关键技术[J]. 锻造与冲压, 2011(7):52-55. LI Yuqiang, WANG Yong, TIAN Hua, et al. The Key Stamping Technology of Tailor-welded Blank with Different Thickness[J]. Forging & Metalforming, 2011(7):52-55.
[3] 曹彪, 魏阿梅.差厚激光拼焊板焊缝偏移产生的原因与控制方法[J].模具工业,2014,40(1):35-39. CAO Biao, WEI Amei. Cause of Weld Offset in Laser Tailor Welded Blanks with Different Thickness and Its Control Methods[J]. Die & Mould Industry, 2014,40(1):35-39.
[4] MIN K B, KIM K S, KANG S S. A Study on Resistance Welding in Steel Sheets Using a Tailor-welded Blank (1st Report) : Evaluation of Upset Weldability and Formability[J]. Journal of Materials Processing Tech., 2000, 101(1/3): 186-192.
[5] KOROUYEH R S, NAEINI H M, TORKAMANY M J, et al. Experimental and Theoretical Investigation of Thickness Ratio Effect on the Formability of Tailor Welded Blank[J]. Optics & Laser Technology, 2013, 51(10):24-31.
[6] CAO J, KINSEY B L. Adaptive Method and Apparatus for Forming Tailor Welded Blanks: US 5941110 A[P]. 1999-08-24.
[7] HEO Y M, WANG S H, KIM H Y, et al. The Effect of the Drawbead Dimensions on the Weld-line Movements in the Deep Drawing of Tailor-welded Blanks[J]. Journal of Materials Processing Tech., 2001, 113(1):686-691.
[8] 朱元右, 姜银方, 杨继昌,等. 拼焊板冲压成形中的焊缝移动分析[J]. 中国机械工程, 2006, 17(15):1618-1622.ZHU Yuanyou, JIANG Yinfang, YANG Jichang, et al. Analysis of Weld-line Movement in Tailor-welded Blanks' formation[J]. China Mechanical Engineering, 2006, 17(15):1618-1622.
[9] HE S. Formability Enhancement for Tailor-welded Blanks Using Blank Holding Force Control[J]. Journal of Manufactu-ring Science & Engineering, 2003, 125(3):461-467.
[10] TANG B T, ZHAO Z, WANG Y. One-step FEM-based Evaluation of Weld Line Movement and Development of Blank in Sheet Metal Stamping with Tailor-welded Blanks[J]. International Journal of Advanced Manufacturing Technology, 2007, 35(3/4):268-279.
[11] KU T W, KANG B S, PARK H J. Tailored Blank Design and Prediction of Weld Line Movement Using the Backward Tracing Scheme of Finite Element Method[J]. International Journal of Advanced Manufacturing Technology, 2005, 25(1/2):17-25.
[12] 龚志辉, 李光耀, 钟志华. 基于网格映射法实现修边线的精确计算[J]. 湖南大学学报(自然科学版), 2008, 35(12): 18-22.GONG Zhihui, LI Guangyao, ZHONG Zhihua. Realization of Accurate Calculation for Trimming Line Based on Grid Mapping[J]. Journal of Hunan University(Natural Sciences), 2008, 35(12): 18-22.