摘要
汽车覆盖件包边作为覆盖件冲压成形的最后一个步骤,其成形质量对覆盖件边缘的外观质量以及整个覆盖件的外形尺寸精度有着重要的影响。汽车覆盖件包边模具结构的设计决定了最终的包边质量,在整个包边模具的设计中,预包边机构是包边模具设计的关键。本文对模具包边中预包边的运动进行了分析,对预包边机构的设计和包边的成形仿真进行了研究,主要包括以下几方面:
(1)对凸轮机构模具包边中的预包边机构进行分类,分析各类预包边机构的运动特点。对各类预包边机构的运动学公式进行了推导,分析其中各个机构参数对预包边机构运动的影响,并指出复合运动机构中弹簧参数对预包边机构运动路线的影响,提出复合机构保证预包边质量稳定的条件。
(2)将预包边机构的运动方程应用到包边有限元仿真建模中,建立不同预包边运动的包边有限元模型,通过仿真结果分析了不同预包边对包边板料所产生的影响。采用拉丁超立方采样法,对终包边有重要影响的参数进行仿真试验设计,运用多元线性回归方法对仿真结果进行分析,总结并分析各个参数对包边卷入卷出的影响。
(3)对包边模预包边机构设计方法进行了研究,分析了各个步骤中所要考虑的因素,并总结出预包边机构建立的流程。在分析预包边机构建立方法的基础上,针对某轿车车门的包边特点设计了包边模预包边机构。采用显示有限元法建立了该包边模具的有限元仿真模型。根据仿真结果,对初始建立的包边模型包边中所存在的缺陷进行了分析,并对模型做出相应的修改。最后通过检验该模具实际试产的样品,验证修改后模型的正确性。
本文中对预包边机构运动参数的分析,为预包边机构的设计提供了参考。可以将预包边运动方程应用到采用类似机构的包边有限元仿真中,得到更为精确的仿真结果。采用多元线性回归法分析包边中卷入卷出和包边参数的关系,为包边参数的选取提供参考。
As the last step of the automotive panels stamping, hemming has significant impact on the forming quality of the appearance and the dimensions on the edge of the automotive panels. The structure design determines the production quality of the hemming die, and the pre-hem mechanism is the most important part of it. The kinematic of pre-hem mechanism was analysed, the design of pre-hem structure and the FEM simulation of hemming was studied, including the following research work:
(1) Classify the pre-hem structure of the hemming die according to the mechanism characteristic, and the kinetic equations of pre-hem motion were deduced, analysis the impact of the pre-hem parameters on the quality of hemming, and the impact of springs on the combined pre-hem motion. And point out the constraint condition of the combined motion pre-hem to have a steady pre-hem quality.
(2) The kinetic equations of pre-hem motion were applied in the hemming FEM modeling, and the various hemming FEM model were built. The impact of pre-hem motion on hemming quality is analyzed based on the FEM results. Design the simulation experiments based on Latin hypercube sampling, analysis the results using the multiple liner regression analysis and summarize the impact of the parameters on the hemming roll in and roll out.
(3) The modeling method of pre-hem structure was studied, and the factors in each step of the modeling was analysed, the flow chart of the pre-hem structure building was summarized. A car door hemming mechanism was designed according to the characteristic. The FEM model of this hemming mechanism was built using explicit FEM method. Eliminate the defects of the die by modifying the die based on the analysis of the FEM results. The inspections on the product demonstrated the validity of the modification.
The kinematic analysis of pre-hem in this thesis can provide references for the design of pre-hem mechanism. The pre-hem kinematic equations can be used to all the FEM simulation of similar hemming to obtain a more accurate simulation results. Using multiple liner regression analysis the relation of the hemming defects and the hemming parameters can provide references for the hemming parameters selection.
引文
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