粘性连接技术在某轿车车顶的应用研究
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摘要
粘接是借助粘接剂在固体表面上所产生的粘合力，将同种或不同种材料牢固地连接在一起的方法。相比机械紧固和点焊，粘接减少了在接头边缘的应力集中，因此提供了更好的抗疲劳性能；粘接还能够连接不兼容的材料，因为粘接层可以阻止不兼容材料的相互亲密接触，从而防止电偶腐蚀；粘接还具有较高的剪切强度，较好的耐腐蚀和密封等性能。
目前，全球范围的能源和环境问题已经出现，这就要求汽车向轻量化的方向发展。汽车零部件的连接是汽车制造中的关键技术之一，目前车身制造中运用最多的连接方式是焊接，但由于成本和技术瓶颈等原因，焊接不能满足汽车制造的某些要求。粘接技术是一种成本低、设备简单、工艺简便、实用性很强的技术。随着高强度粘接剂的发展，粘接接头的强度已经能够满足车身性能的要求。因此，对粘接技术的研究有很好的应用价值。
本文首先介绍国内外在单搭接粘接接头方面的研究，粘接在汽车上应用的静态研究和粘接的碰撞研究。对这些研究中使用的研究方法和得到的研究成果做了简单介绍。
接着，在商用软件ABAQUS中建立试验单搭接粘接接头的有限元模型，模拟试验中的载荷加载方式和边界条件，然后对模型进行仿真计算，由试验结果得到沿着搭接接头的应变曲线，对有限元模拟结果进行后处理得到相应的曲线，比较有限元仿真结果和实验得到的结果。
然后，建立某轿车粘接式车顶有限元模型，包括五个不同粘接层厚度的模型，并对建立的有限元模型进行静强度分析，对所建模型分别施加弯曲和扭转载荷，比较粘接层厚度对模型中各部件应力的影响，从中选出静强度较好的粘接模型。建立某轿车焊接式车顶有限元模型，粘接处使用前面选出的粘接层，对焊接式车顶模型进行有限元分析，比较粘接式车顶模型和焊接式车顶模型的分析结果。
最后，选取静强度分析中静强度较好的粘接式车顶模型，对焊接式车顶模型和选出的粘接式车顶模型施加相同的碰撞载荷，然后对两个模型的碰撞结果进行对比分析，通过应力分析结果比较两种模型的抗撞性好坏，通过两种模型的吸能曲线比较两种模型吸能能力的好坏。
Bonding is a method which can firmly connected with the same kind or different kindsof materials by the adhesion of the bonding agent on the solid surface. Compared tomechanical fastening and welding, Bonding reduced connector edge of the stressconcentration, thus providing a better fatigue performance; bonding also can connectincompatible materials, because the adhesive layer can prevent non-compatible materialswith each other intimate contact, thus preventing galvanic corrosion; bonding also has a highshear strength, better resistance to corrosion and sealing performance.
Currently, the worldwide energy and environmental issues have emerged, whichrequires the car to the direction of lightweight. The connection of the auto parts is the keytechnologies in the automobile manufacturing, welding is the most widely used in car bodymanufacturing connection, welding can not meet some requirements of car manufacturers,attributed to the reasons such as cost and technical bottlenecks. Bonding technology is alow-cost, simple equipment, simple process and very practical technology. With thedevelopment of high-strength adhesives, the adhesive joint strength has been able to meet theperformance requirements of the body. Therefore, Bonding technology research is goodvalue.
First of all, this paper introduces the study of the adhesive joint, static research ofadhesive bonding applications in the automotive, and bonding study of the collision at homeand abroad. I make a brief introduction to the research methods used in the study andobtained research results.
Secondly, Finite element model of the experimental single-lap bonded joints isestablished in the commercial software ABAQUS, simulating the test load loading mode andboundary conditions. The strain curve along the lap joint direction are obtained from theexperimental results, In the simulation results post-processing the corresponding curve is obtained.Then compare the simulation results of finite element simulation and theexperimental results.
Then, Finite element model of the bonding type roof of a vehicle is established,including five models of different adhesive layer thickness. Static strength analysis of thefinite element model is conducted, by imposing bending and torsional loads on the model,comparing the influence of relatively sticky Layer thickness to the stress on variouscomponents of the model, choosing the better stress distribution of the bonding models. Next,finite element model of the welded roof of a vehicle is established, using the selectedadhesive layer thickness of previous bonding model in the welding model where needbonding. Finally, static strength analysis of the welding model is conducted, imposing thesame loads of the bonding model simulation, comparing analysis results of the bondingmodel and welding model.
Finally, Welding model previously established and the bonding model with better staticstrength in the static strength analysis are used, with the same collision loads applied on theselected bonding model and welding model; Subsequently finite element analysis of twomodels are conducted, by comparing the stress analysis results the model with bettercrashworthiness are got. While by comparing energy absorption curves of the two modelsthe model with better energy absorption capability will be obtained.
目前，全球范围的能源和环境问题已经出现，这就要求汽车向轻量化的方向发展。汽车零部件的连接是汽车制造中的关键技术之一，目前车身制造中运用最多的连接方式是焊接，但由于成本和技术瓶颈等原因，焊接不能满足汽车制造的某些要求。粘接技术是一种成本低、设备简单、工艺简便、实用性很强的技术。随着高强度粘接剂的发展，粘接接头的强度已经能够满足车身性能的要求。因此，对粘接技术的研究有很好的应用价值。
本文首先介绍国内外在单搭接粘接接头方面的研究，粘接在汽车上应用的静态研究和粘接的碰撞研究。对这些研究中使用的研究方法和得到的研究成果做了简单介绍。
接着，在商用软件ABAQUS中建立试验单搭接粘接接头的有限元模型，模拟试验中的载荷加载方式和边界条件，然后对模型进行仿真计算，由试验结果得到沿着搭接接头的应变曲线，对有限元模拟结果进行后处理得到相应的曲线，比较有限元仿真结果和实验得到的结果。
然后，建立某轿车粘接式车顶有限元模型，包括五个不同粘接层厚度的模型，并对建立的有限元模型进行静强度分析，对所建模型分别施加弯曲和扭转载荷，比较粘接层厚度对模型中各部件应力的影响，从中选出静强度较好的粘接模型。建立某轿车焊接式车顶有限元模型，粘接处使用前面选出的粘接层，对焊接式车顶模型进行有限元分析，比较粘接式车顶模型和焊接式车顶模型的分析结果。
最后，选取静强度分析中静强度较好的粘接式车顶模型，对焊接式车顶模型和选出的粘接式车顶模型施加相同的碰撞载荷，然后对两个模型的碰撞结果进行对比分析，通过应力分析结果比较两种模型的抗撞性好坏，通过两种模型的吸能曲线比较两种模型吸能能力的好坏。
Bonding is a method which can firmly connected with the same kind or different kindsof materials by the adhesion of the bonding agent on the solid surface. Compared tomechanical fastening and welding, Bonding reduced connector edge of the stressconcentration, thus providing a better fatigue performance; bonding also can connectincompatible materials, because the adhesive layer can prevent non-compatible materialswith each other intimate contact, thus preventing galvanic corrosion; bonding also has a highshear strength, better resistance to corrosion and sealing performance.
Currently, the worldwide energy and environmental issues have emerged, whichrequires the car to the direction of lightweight. The connection of the auto parts is the keytechnologies in the automobile manufacturing, welding is the most widely used in car bodymanufacturing connection, welding can not meet some requirements of car manufacturers,attributed to the reasons such as cost and technical bottlenecks. Bonding technology is alow-cost, simple equipment, simple process and very practical technology. With thedevelopment of high-strength adhesives, the adhesive joint strength has been able to meet theperformance requirements of the body. Therefore, Bonding technology research is goodvalue.
First of all, this paper introduces the study of the adhesive joint, static research ofadhesive bonding applications in the automotive, and bonding study of the collision at homeand abroad. I make a brief introduction to the research methods used in the study andobtained research results.
Secondly, Finite element model of the experimental single-lap bonded joints isestablished in the commercial software ABAQUS, simulating the test load loading mode andboundary conditions. The strain curve along the lap joint direction are obtained from theexperimental results, In the simulation results post-processing the corresponding curve is obtained.Then compare the simulation results of finite element simulation and theexperimental results.
Then, Finite element model of the bonding type roof of a vehicle is established,including five models of different adhesive layer thickness. Static strength analysis of thefinite element model is conducted, by imposing bending and torsional loads on the model,comparing the influence of relatively sticky Layer thickness to the stress on variouscomponents of the model, choosing the better stress distribution of the bonding models. Next,finite element model of the welded roof of a vehicle is established, using the selectedadhesive layer thickness of previous bonding model in the welding model where needbonding. Finally, static strength analysis of the welding model is conducted, imposing thesame loads of the bonding model simulation, comparing analysis results of the bondingmodel and welding model.
Finally, Welding model previously established and the bonding model with better staticstrength in the static strength analysis are used, with the same collision loads applied on theselected bonding model and welding model; Subsequently finite element analysis of twomodels are conducted, by comparing the stress analysis results the model with bettercrashworthiness are got. While by comparing energy absorption curves of the two modelsthe model with better energy absorption capability will be obtained.
引文
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[3] L. Lu1, H. Y. Zhao*1, Z. P. Cai1, P. C. Wang2, John Fickes3. Modelling of deformationand failure of crash toughened adhesive bonded lap shear joints[J]. Science andTechnology of Weld and Joining,2008：479-483.
[4]李龙，胡平，刘立忠.不同胶层厚度单搭接接头剪切试验与强度预测[J].农业机械学报[J],2010（12）：17-21.
[5]郑小玲，娜日松，游敏，焦建凯.胶瘤对单搭接胶接接头强度的影响[J].三峡大学学报：自然科学版，2001（6）：530－532.
[6]余海洲，游敏，郑小玲，刘文俊.胶瘤中嵌入金属对单搭接接头的影响[J].中国粘接剂,2005（5）：21－23.
[7]杜正兴,高宗战,岳珠峰.胶瘤对单搭接胶接接头应力分布影响的数值分析[J].机械强度,2008,30(5)：839～843.
[8]赵波.刚度非平衡胶接接头的二维应力分析[J].工程力学，2008（12）：6－13.
[9] Bo Zhao，Zhen-Hua Lu, Yi-Ning Lu. Closed-form solutions for elastic stress–strainanalysis in unbalanced adhesive single-lap joints considering adherend deformations andbond thickness. International Journal of Adhesion&Adhesives,2011.
[10] Zhao B, Lu Z-H. Mech Adv Mater Struct[J].2009;16(2):130.
[11] H.S.da Costa Mattos, E.M.Sampaio, A. H. Monteiro. Static failure analysis of adhesivesingle lap joints[J]. International Journal of Adhesion&Adhesives,2010,1－9.
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[23] P.N.B.Reisa, J.A.M.Ferreirab, F.Antunesb. Effect of adherend’s rigidity on the shearstrength of single lap adhesive joints[J]. International Journal of Adhesion&Adhesives,2011(31),193–201.
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[25] Young Tae Kim, Min Jung Lee, Byung Chai Lee. Simulation of adhesive joints usingthe superimposed finite element method and a cohesive zone model[J].InternationalJournal of Adhesion&Adhesives,2010.
[26] J.P.M. Gon－calves, M.F.S.F.de Moura, P.M.S.T.de Castro. A three-dimensional finiteelement model for stress analysis of adhesive joints[J]. International Journal ofAdhesion&Adhesives,2002(22),357–365.
[27] Robert L.Thomas, a Waldemar G. de Rijk, PhD, DDS, b and Carla A. Evans, DDS,DMScc. Tensile and shear stresses in the orthodontic attachment adhesive layer with3D finite element analysis[J]. American Journal of Orthodontics and DentofacialOrthopedics,2009,530-532.
[28] H.Zhao, X.Duan, M.Ma, L.Lu, Z.P.Cai, P.C.Wang and J.D.Fickes. Dynamiccharacteristics of adhesive bonded high strength steel joints[J]. Science and Technologyof Weld and Joining,2010,1-5.
[29] T.Carlberger, U.Stigh. An explicit FE-model of impact fracture in an adhesive joint[J].Engineering Fracture Mechanic,2007,2247-2262.
[30]张林涛.轿车风挡对白车身静态刚度影响的有限元分析[J].天津汽车，2009（6），26－28.
[31]李巍.客车粘接式车窗玻璃有限元建模方法研究[D].长春:吉林大学汽车工程学院，2007.
[32] Nagarjuna Yagam and Shuvra Das. Finite Element Modeling of Adhesive JointBehavior for Automotive Applications[J]. SAE World Congress Detroit,2006,3-8.
[33] T.A.Barnes, I.R.Pashby. Joining techniques for aluminium spaceframes used inautomobiles Part II－adhesive bonding and mechanical fasteners[J]. Journal ofMaterials Processing Technology,2000,72–79.
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[2]范叶，杨沿平，孟先春，唐杰.汽车轻量化及其实施途径[J].汽车工业研究，2006，7期，40－42.
[3] L. Lu1, H. Y. Zhao*1, Z. P. Cai1, P. C. Wang2, John Fickes3. Modelling of deformationand failure of crash toughened adhesive bonded lap shear joints[J]. Science andTechnology of Weld and Joining,2008：479-483.
[4]李龙，胡平，刘立忠.不同胶层厚度单搭接接头剪切试验与强度预测[J].农业机械学报[J],2010（12）：17-21.
[5]郑小玲，娜日松，游敏，焦建凯.胶瘤对单搭接胶接接头强度的影响[J].三峡大学学报：自然科学版，2001（6）：530－532.
[6]余海洲，游敏，郑小玲，刘文俊.胶瘤中嵌入金属对单搭接接头的影响[J].中国粘接剂,2005（5）：21－23.
[7]杜正兴,高宗战,岳珠峰.胶瘤对单搭接胶接接头应力分布影响的数值分析[J].机械强度,2008,30(5)：839～843.
[8]赵波.刚度非平衡胶接接头的二维应力分析[J].工程力学，2008（12）：6－13.
[9] Bo Zhao，Zhen-Hua Lu, Yi-Ning Lu. Closed-form solutions for elastic stress–strainanalysis in unbalanced adhesive single-lap joints considering adherend deformations andbond thickness. International Journal of Adhesion&Adhesives,2011.
[10] Zhao B, Lu Z-H. Mech Adv Mater Struct[J].2009;16(2):130.
[11] H.S.da Costa Mattos, E.M.Sampaio, A. H. Monteiro. Static failure analysis of adhesivesingle lap joints[J]. International Journal of Adhesion&Adhesives,2010,1－9.
[12] He X, Oyadiji SO. Proceedings of ESDA2004. Manchester;2004,397.
[13] He X, Oyadiji SO. Proceedings of ESDA2004. Manchester;2004,405.
[14] Haghani R, Al-Emrani M, Kliger RJ. Compos Mater2010;44(3),287.
[15] Fessel G, Broughton JG, Fellows NA, Durodola JF. Hutchinson AR. Int J Adhes Adhes2007,27(7),574.
[16] Zhao X, Adams RD, da Silva LFM. Int J Adhes Adhes2010,30(2),63.
[17] Grant LDR, Adams RD, da Silva LFM. Int J Adhes Adhes2009,29(4),405.
[18] Cat-Tan Hoang-Ngoc. Eric Paroissien. Simulation of single-lap bonded and hybrid(bolted/bonded) joints with flexible adhesive[J]. International Journal of Adhesion&Adhesives,2010(30),117–129.
[19]孔凡荣,游敏,郑小玲,杨春梅.搭接长度对胶接接头工作应力分布影响的数值分析[J].机械强度,2004，26(2)：213—217.
[20] DI′az J, Romera L, Herna′ndez S. Baldomir A. Int J Adhes Adhes2010,30(3),178.
[21] Gang Lia, Pearl Lee-Sullivana, Ronald W. Thringb. Nonlinear finite element analysis ofstress and strain distributions across the adhesive thickness in composite single-lapjoints[J]. Composite Structures,1999(46),395–403.
[22] Antonio F.Avila, Plinio de O. Bueno. An experimental and numerical study on adhesivejoints for composites[J]. Composite Structures,2004(64),531–537.
[23] P.N.B.Reisa, J.A.M.Ferreirab, F.Antunesb. Effect of adherend’s rigidity on the shearstrength of single lap adhesive joints[J]. International Journal of Adhesion&Adhesives,2011(31),193–201.
[24] Jin Woo Parka, Jae Woong Hwanga, Yong Hyup Kimb. Efficient finite element analysisusing mesh superposition technique[J]. Finite Elements in Analysis and Design,2003(39),619–638.
[25] Young Tae Kim, Min Jung Lee, Byung Chai Lee. Simulation of adhesive joints usingthe superimposed finite element method and a cohesive zone model[J].InternationalJournal of Adhesion&Adhesives,2010.
[26] J.P.M. Gon－calves, M.F.S.F.de Moura, P.M.S.T.de Castro. A three-dimensional finiteelement model for stress analysis of adhesive joints[J]. International Journal ofAdhesion&Adhesives,2002(22),357–365.
[27] Robert L.Thomas, a Waldemar G. de Rijk, PhD, DDS, b and Carla A. Evans, DDS,DMScc. Tensile and shear stresses in the orthodontic attachment adhesive layer with3D finite element analysis[J]. American Journal of Orthodontics and DentofacialOrthopedics,2009,530-532.
[28] H.Zhao, X.Duan, M.Ma, L.Lu, Z.P.Cai, P.C.Wang and J.D.Fickes. Dynamiccharacteristics of adhesive bonded high strength steel joints[J]. Science and Technologyof Weld and Joining,2010,1-5.
[29] T.Carlberger, U.Stigh. An explicit FE-model of impact fracture in an adhesive joint[J].Engineering Fracture Mechanic,2007,2247-2262.
[30]张林涛.轿车风挡对白车身静态刚度影响的有限元分析[J].天津汽车，2009（6），26－28.
[31]李巍.客车粘接式车窗玻璃有限元建模方法研究[D].长春:吉林大学汽车工程学院，2007.
[32] Nagarjuna Yagam and Shuvra Das. Finite Element Modeling of Adhesive JointBehavior for Automotive Applications[J]. SAE World Congress Detroit,2006,3-8.
[33] T.A.Barnes, I.R.Pashby. Joining techniques for aluminium spaceframes used inautomobiles Part II－adhesive bonding and mechanical fasteners[J]. Journal ofMaterials Processing Technology,2000,72–79.
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