车身覆盖件冲压成形仿真及工艺优化
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摘要
在车身覆盖件设计过程中，由于技术能力、开发周期和开发成本等诸多因素的限制，技术人员不可能仅依靠大量的传统试错分析对覆盖件的成形方案进行改进。因此有限元数值模拟技术逐渐成为提高车身开发水平不可缺少的重要工具。
现有的覆盖件成形研究主要以验证是否能避免出现明显的产品缺陷为主，对于如何在设计阶段合理确定车身覆盖件各个参数等问题缺乏全面、系统的研究。因此研究拉深成形的变压边力技术，并且运用正交试验的方法，寻求适用于车身覆盖件成形过程的最优化参数组合，具有重要的工程意义和研究价谊。
本文较系统的阐述和讨论了冲压成形仿真非线性有限元理论，包括材料模型、单元算法、接触及摩擦问题的处理等。讨论了冲压仿真有限元建模方法，并对仿真过程中关键问题做了较深入的研究，在此基础上对大型车身覆盖件的冲压过程进行了仿真。主要内容如下：
1．系统阐述了车身覆盖件冲压成形仿真非线性有限元理论，讨论了仿真中冲压的三种材料模型，并在参考有关文献的基础上给出了Hill和Barlat模型的增量型弹塑性本构关系的显式表达及求解；阐述了适合于冲压仿真的BT壳单元理论和接触及摩擦问题的处理等。
2．研究了车身覆盖件冲压成形仿真建模的关键问题，包括模具型面的设计、拉延筋的处理、压边圈的处理和压边力的计算等。
3．详细介绍了利用DYNAFORM软件对江都汽车覆盖件厂生产的保险杠有限元建模过程。
4．基于前面建立的保险杠有限元模型，运用正交实验的方法，对拉延筋深度、压边力大小、虚拟凸模冲压速度、凸凹模间隙四个参数进行了优化组合，同时具体分析了虚拟凸模速度和压边力对保险杠成形质量的影响。最后选取优化后的工艺参数进行了仿真，与实际生产的零件进行了对比分析，并提出了改进措施。
Due to limitations of the technique, the lead time and the development cost in the design phase, an acceptable forming solution is not easy to obtain with a large number of trial-and-error runs. Numerical simulation technology, a quickly developing engineering analysis method, has laid a foundation for the automotive of the forming process design. It has been an indispensable tool to speed up the development of automotive.
Most of the existing research on automotive panel forming is focused on verifying whether product defects appear. However, comprehensive and systematic work has rarely been done on how to improve the performance figures of automotive panel in the design phase. Optimization of funning process is a very difficulty problem due to design nonlinearity and huge computational cost of numerical simulations. Therefore, there is notable engineering significance and academic value to seek for a numerical simulation based optimization method for automotive panel forming process.
In this paper, the non-linear explicit finite element theory is studied systematicly, which include material models, element algorithm and contact handling methods etc. The FE modeling methods of stamping simulation are investigated and a comparatively deep study on the key points of process. And on the basis of them, the forming simulation of large automotive panels is made and results analyzed.
1. The non-linear finite element theory for automotive panel forming simulation is systematically expounded and discussed. Three usually used material models for stamping simulation are discussed and studied, and based on the reference of other research papers, the explicit description of Elastic-Plastic Materials for Hill's and Barlat's yield models are established. BT shell element theory and contact handling algorithm are also expounded in this paper.
2. The key parameters in the simulation of stamp metal forming are studied, which include die-face, drawbead and blank-holder force.
3. introduce the detailed processes of molding to a part of bumper base on DYNAFORM
4. A part of bumper on automotive forming simulation is carried out in the way of orthogonal and the results are discussed, moreover, improved measure is put forward.
现有的覆盖件成形研究主要以验证是否能避免出现明显的产品缺陷为主，对于如何在设计阶段合理确定车身覆盖件各个参数等问题缺乏全面、系统的研究。因此研究拉深成形的变压边力技术，并且运用正交试验的方法，寻求适用于车身覆盖件成形过程的最优化参数组合，具有重要的工程意义和研究价谊。
本文较系统的阐述和讨论了冲压成形仿真非线性有限元理论，包括材料模型、单元算法、接触及摩擦问题的处理等。讨论了冲压仿真有限元建模方法，并对仿真过程中关键问题做了较深入的研究，在此基础上对大型车身覆盖件的冲压过程进行了仿真。主要内容如下：
1．系统阐述了车身覆盖件冲压成形仿真非线性有限元理论，讨论了仿真中冲压的三种材料模型，并在参考有关文献的基础上给出了Hill和Barlat模型的增量型弹塑性本构关系的显式表达及求解；阐述了适合于冲压仿真的BT壳单元理论和接触及摩擦问题的处理等。
2．研究了车身覆盖件冲压成形仿真建模的关键问题，包括模具型面的设计、拉延筋的处理、压边圈的处理和压边力的计算等。
3．详细介绍了利用DYNAFORM软件对江都汽车覆盖件厂生产的保险杠有限元建模过程。
4．基于前面建立的保险杠有限元模型，运用正交实验的方法，对拉延筋深度、压边力大小、虚拟凸模冲压速度、凸凹模间隙四个参数进行了优化组合，同时具体分析了虚拟凸模速度和压边力对保险杠成形质量的影响。最后选取优化后的工艺参数进行了仿真，与实际生产的零件进行了对比分析，并提出了改进措施。
Due to limitations of the technique, the lead time and the development cost in the design phase, an acceptable forming solution is not easy to obtain with a large number of trial-and-error runs. Numerical simulation technology, a quickly developing engineering analysis method, has laid a foundation for the automotive of the forming process design. It has been an indispensable tool to speed up the development of automotive.
Most of the existing research on automotive panel forming is focused on verifying whether product defects appear. However, comprehensive and systematic work has rarely been done on how to improve the performance figures of automotive panel in the design phase. Optimization of funning process is a very difficulty problem due to design nonlinearity and huge computational cost of numerical simulations. Therefore, there is notable engineering significance and academic value to seek for a numerical simulation based optimization method for automotive panel forming process.
In this paper, the non-linear explicit finite element theory is studied systematicly, which include material models, element algorithm and contact handling methods etc. The FE modeling methods of stamping simulation are investigated and a comparatively deep study on the key points of process. And on the basis of them, the forming simulation of large automotive panels is made and results analyzed.
1. The non-linear finite element theory for automotive panel forming simulation is systematically expounded and discussed. Three usually used material models for stamping simulation are discussed and studied, and based on the reference of other research papers, the explicit description of Elastic-Plastic Materials for Hill's and Barlat's yield models are established. BT shell element theory and contact handling algorithm are also expounded in this paper.
2. The key parameters in the simulation of stamp metal forming are studied, which include die-face, drawbead and blank-holder force.
3. introduce the detailed processes of molding to a part of bumper base on DYNAFORM
4. A part of bumper on automotive forming simulation is carried out in the way of orthogonal and the results are discussed, moreover, improved measure is put forward.
引文
[1] 林忠钦．车身覆盖件冲压成形仿真[M]．北京：机械工业出版社，2004．10
[2] 陈文亮．板料成形CAE教程[M]．北京：机械工业出版社，2005．2
[3] 胡轶敏，林忠钦，秦长灯．车身覆盖件冲压成形动态仿真的研究进展[J]．力学进展．2000(4)：100-106
[4] 陈炜，林忠钦，陈关龙．汽车模具CAD／CAM技术应用研究和发展趋势[J]．金属成形工艺，1999，(2)：1-3
[5] 陈炜，林忠钦，徐伟力，陈关龙．现代汽车覆盖件模具设计方法研究[J]．中国机械工程，2000，11(增刊)：77-79
[6] 徐康聪．汽车车身覆盖件成形过程的计算机数值分析与应用研究．博士学位论文，1995
[7] 阮雪榆．21世纪数字化塑性成形技术与科学．模具技术，2003(2)：3-8
[8] Grip. P. M. The Computer-Adied Design of Modular Fixturing Systems[J]. The International Journal of Advanced Manufacturing Technology. 2001(2): 75-88.
[9] Duarte J F, Horha A B da. A brief description of an S-Rail Benchmark. In: Proc. of NUMISHEEI'96. Detroit, 1996. 336-343
[10] 张佑生，王雷刚，田卫东．智能CAD方法及应用[J]．合肥工业大学学报(自然科学版)，1999(10)：1-5．
[11] 源清，肖文．CAD技术发展历程概览[J]．计算机辅助设计与造，1998(1)：3-6
[12] Wang N M, Budiansky B. Analysis of sheet metal stamping by a finite element methods, Journal of Applied Mechanics, ASME, 1978, 100: 73-82
[13] 乔端，钱仁根．非线性有限元法及其在塑性加工中的应用[M]．北京：冶金工业出版社，1990
[14] Kubli W, Reissner J. Optimization of sheet-metal formiong processes using the special-purpose program AUTOFORM. In: Pros of NUMISHEET' 93 Numerical Simulation of 3-D sheet Metal Forming Processes Verification of Simmlation with Fxpermtent. Tokyo, 1993. 292-305
[15] 王瑁成，邵敏．有限单元法基本原理和数值方法[M]．北京：清华大学出版社，1997
[16] 王仁，熊祝华，黄文彬．塑性力学基础[M]．北京：科学出版社，1982
[17] 徐秉业，贸炎，刘信声．弹塑性力学及其应用[M]．北京：国防工业出版社，1991
[18] Tang S C. Finite element prediction of the deformed shape of automobile trunk deck-lid during the binder-wrap stage. In: Chen C C. Experiment Verification of Process Models. ASM. Metals Park, OH. 1981. 189-203
[19] Tang S C. Analys of spring-back in sheet forming operation. In: Proc of The Second Int. Conference on Technology of Plasticity (ICTP). Stuttgart, 1987. 193-197
[20] Tang S C. Application of membrane theory to automotive sheet metal forming analysis. In. Chenot, Wood, Zienkiewiez. Numerical Methods in Industrial Forming Processes. Rotterdam: Balkema Press, 1992. 549 -554
[21] Karl Kuzman, Blaz Nardin, Marjan Kovac, Boris Jurkosek. The integration of rapid prototyping and CAE in mould manufacturing[J], Materials Processing Technology, 2001, 279-283.
[22] 胡轶敏．车身覆盖件冲压成形的三维仿真与试验研究上海交通大学博士学位论文，1999
[23] 孙家广，杨长贵．计算机图形学[M]．北京：清华大学出版社，1995
[24] 郭春生，汤宝骏，孙继明．汽车大型覆盖件模具[M]．北京：国防工业出版社，1993
[25] 柳百成．采用先进铸造技术，促进汽车工业发展—参加第三届亚洲铸造会议总结[J]，1995．12
[26] 肖景容．模具CAD／CAM发展趋势[J]．模具工业，1990(9)：30-34
[27] 唐荣锡．CAD／CAM技术[M]．北京：北京航空航天大学出版社，1994
[28] 张子公，顾为兵，蒋险峰．提高模具结构CAD效率和柔性的有效途径[J]．模具工业，1996(5)：3-8
[29] 郑可煌，张弘．实用冲压模具设计手册[M]．北京：宇航出版社，1990
[30] 崔令江．汽车覆盖件冲压成形技术[M]．北京：机械工业出版社，2003．6
[31] C Weidemann. The blankholder action of drawbeads. In: Proceedings of 10th biennial IDDRG congress, 1978. 79-85
[32] P Chabrand, F Dubois, JC Gelin, Modeling drawbeads in sheet metal forming. International Journal of Mechanical Science, 1996, 38 (1):59-77
[33] H D Nine. Drawbead force in sheet metal forming. In: Koistinen D P, Wang N M, etc. Mechanics of sheet metal forming. New York: Plenum Press, 1978. 179-211
[34] H D Nina. New drawbead concepts far sheet metal forming[J]. Journal of applied metal working, 1982, 2 (3): 185-192
[35] N M Wag, V C Shah. Drawbead design and Performance. Journal of Material Shaping Technology, 1991, 9: 21-26
[36] John A Schey. Geometric factors affecting results from the drawbead simulation (DBS) test. Journal of the society of tribologists and lubriation engineers, 1993, 6: 255-260
[37] John A Schey. Speed effects in drawbead simulation. Journal of Materials Accessing Technology, 1996(57): 146-154
[38] 杨玉英．大型薄板成形技术[M]．北京：国防工业出版社，1996
[39] 杨虎等，数理统计[M]．北京：高等教育出版社，1993
[40] 王东哲，娄臻亮，张永清，何丹农．动压力机压边组件的新技术及应用[J]．创造技术与机床，2004(4)
[41] 陈景松，王平，蔡军．现代轿车制造业中的压力机[J]．．锻压装备与制造技术，2003，38(1)
[42] L fratiru, F Micari. Investigation effective blankholder Force paths to improve the maximum component height in deep drawing process. Numisheet'99
[43] Yu-wei Wang, S Ali Sacedy, S A Majlessi and J E Beard Strain path effects on the modified FLD caused by variable blank holder force. SAE Trans. of Matenals & Manufacturing, 1995, No. 950695. 522-531
[44] R Kergen, P Jodogne. Computerized Control of the blankho]der presure on deep drawing presses. Society of Autotive Engineers technical paper, NO. 920433, Warrendale, PA, 1992
[45] 王东哲，娄臻亮，张永清，何丹农．板料变压边力拉深成形方形盒数值模拟．上海交通大学学报，2001，35(10)
[46] 孙成智，陈关龙，李淑慧，林忠钦．变压边力对矩形件成形性能的影响．塑性工程学报，2003，10(4)
[47] 孙成智，陈关龙，林忠钦，李淑兼．利用变压边力控制技术改善盒形件成形性能．上海交通大学学报，2003，34(10)
[48] 孙成智，陈关龙，林忠钦，张卫刚．基于数值摸拟的变压边力优化设计．上海交通大学学报，2004
[49] 孙成智．基于变压边力的薄板冲压成形理论与实验研究．上海交通大学博士学位论文，2004
[50] K Siegert, M Ziegler Pulsating Blankbolder force. SAE Trans, of Materials & Manufacturing, 1997, No 970997
[51] M Ahmetoglu et al. Improving drawability of round and non-symmetric part. Society of Automotive Engineers Technical Paper, 1993, No 934287
[2] 陈文亮．板料成形CAE教程[M]．北京：机械工业出版社，2005．2
[3] 胡轶敏，林忠钦，秦长灯．车身覆盖件冲压成形动态仿真的研究进展[J]．力学进展．2000(4)：100-106
[4] 陈炜，林忠钦，陈关龙．汽车模具CAD／CAM技术应用研究和发展趋势[J]．金属成形工艺，1999，(2)：1-3
[5] 陈炜，林忠钦，徐伟力，陈关龙．现代汽车覆盖件模具设计方法研究[J]．中国机械工程，2000，11(增刊)：77-79
[6] 徐康聪．汽车车身覆盖件成形过程的计算机数值分析与应用研究．博士学位论文，1995
[7] 阮雪榆．21世纪数字化塑性成形技术与科学．模具技术，2003(2)：3-8
[8] Grip. P. M. The Computer-Adied Design of Modular Fixturing Systems[J]. The International Journal of Advanced Manufacturing Technology. 2001(2): 75-88.
[9] Duarte J F, Horha A B da. A brief description of an S-Rail Benchmark. In: Proc. of NUMISHEEI'96. Detroit, 1996. 336-343
[10] 张佑生，王雷刚，田卫东．智能CAD方法及应用[J]．合肥工业大学学报(自然科学版)，1999(10)：1-5．
[11] 源清，肖文．CAD技术发展历程概览[J]．计算机辅助设计与造，1998(1)：3-6
[12] Wang N M, Budiansky B. Analysis of sheet metal stamping by a finite element methods, Journal of Applied Mechanics, ASME, 1978, 100: 73-82
[13] 乔端，钱仁根．非线性有限元法及其在塑性加工中的应用[M]．北京：冶金工业出版社，1990
[14] Kubli W, Reissner J. Optimization of sheet-metal formiong processes using the special-purpose program AUTOFORM. In: Pros of NUMISHEET' 93 Numerical Simulation of 3-D sheet Metal Forming Processes Verification of Simmlation with Fxpermtent. Tokyo, 1993. 292-305
[15] 王瑁成，邵敏．有限单元法基本原理和数值方法[M]．北京：清华大学出版社，1997
[16] 王仁，熊祝华，黄文彬．塑性力学基础[M]．北京：科学出版社，1982
[17] 徐秉业，贸炎，刘信声．弹塑性力学及其应用[M]．北京：国防工业出版社，1991
[18] Tang S C. Finite element prediction of the deformed shape of automobile trunk deck-lid during the binder-wrap stage. In: Chen C C. Experiment Verification of Process Models. ASM. Metals Park, OH. 1981. 189-203
[19] Tang S C. Analys of spring-back in sheet forming operation. In: Proc of The Second Int. Conference on Technology of Plasticity (ICTP). Stuttgart, 1987. 193-197
[20] Tang S C. Application of membrane theory to automotive sheet metal forming analysis. In. Chenot, Wood, Zienkiewiez. Numerical Methods in Industrial Forming Processes. Rotterdam: Balkema Press, 1992. 549 -554
[21] Karl Kuzman, Blaz Nardin, Marjan Kovac, Boris Jurkosek. The integration of rapid prototyping and CAE in mould manufacturing[J], Materials Processing Technology, 2001, 279-283.
[22] 胡轶敏．车身覆盖件冲压成形的三维仿真与试验研究上海交通大学博士学位论文，1999
[23] 孙家广，杨长贵．计算机图形学[M]．北京：清华大学出版社，1995
[24] 郭春生，汤宝骏，孙继明．汽车大型覆盖件模具[M]．北京：国防工业出版社，1993
[25] 柳百成．采用先进铸造技术，促进汽车工业发展—参加第三届亚洲铸造会议总结[J]，1995．12
[26] 肖景容．模具CAD／CAM发展趋势[J]．模具工业，1990(9)：30-34
[27] 唐荣锡．CAD／CAM技术[M]．北京：北京航空航天大学出版社，1994
[28] 张子公，顾为兵，蒋险峰．提高模具结构CAD效率和柔性的有效途径[J]．模具工业，1996(5)：3-8
[29] 郑可煌，张弘．实用冲压模具设计手册[M]．北京：宇航出版社，1990
[30] 崔令江．汽车覆盖件冲压成形技术[M]．北京：机械工业出版社，2003．6
[31] C Weidemann. The blankholder action of drawbeads. In: Proceedings of 10th biennial IDDRG congress, 1978. 79-85
[32] P Chabrand, F Dubois, JC Gelin, Modeling drawbeads in sheet metal forming. International Journal of Mechanical Science, 1996, 38 (1):59-77
[33] H D Nine. Drawbead force in sheet metal forming. In: Koistinen D P, Wang N M, etc. Mechanics of sheet metal forming. New York: Plenum Press, 1978. 179-211
[34] H D Nina. New drawbead concepts far sheet metal forming[J]. Journal of applied metal working, 1982, 2 (3): 185-192
[35] N M Wag, V C Shah. Drawbead design and Performance. Journal of Material Shaping Technology, 1991, 9: 21-26
[36] John A Schey. Geometric factors affecting results from the drawbead simulation (DBS) test. Journal of the society of tribologists and lubriation engineers, 1993, 6: 255-260
[37] John A Schey. Speed effects in drawbead simulation. Journal of Materials Accessing Technology, 1996(57): 146-154
[38] 杨玉英．大型薄板成形技术[M]．北京：国防工业出版社，1996
[39] 杨虎等，数理统计[M]．北京：高等教育出版社，1993
[40] 王东哲，娄臻亮，张永清，何丹农．动压力机压边组件的新技术及应用[J]．创造技术与机床，2004(4)
[41] 陈景松，王平，蔡军．现代轿车制造业中的压力机[J]．．锻压装备与制造技术，2003，38(1)
[42] L fratiru, F Micari. Investigation effective blankholder Force paths to improve the maximum component height in deep drawing process. Numisheet'99
[43] Yu-wei Wang, S Ali Sacedy, S A Majlessi and J E Beard Strain path effects on the modified FLD caused by variable blank holder force. SAE Trans. of Matenals & Manufacturing, 1995, No. 950695. 522-531
[44] R Kergen, P Jodogne. Computerized Control of the blankho]der presure on deep drawing presses. Society of Autotive Engineers technical paper, NO. 920433, Warrendale, PA, 1992
[45] 王东哲，娄臻亮，张永清，何丹农．板料变压边力拉深成形方形盒数值模拟．上海交通大学学报，2001，35(10)
[46] 孙成智，陈关龙，李淑慧，林忠钦．变压边力对矩形件成形性能的影响．塑性工程学报，2003，10(4)
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