自冲铆接头动力学分析
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摘要
自冲铆技术是一种冷成型技术,它由冲头将半空心铆钉压下刺穿上板在底板中呈喇叭状张开变形,在两层板或多层板中形成机械内锁。尽管自冲铆是一种新型的薄板连接技术,但是它的机械性能比传统的点焊好。自冲铆技术已在汽车行业得到广泛的应用,因此引起了其它工业领域广泛的兴趣。自冲铆技术被誉为下一代连接技术,是汽车轻量化过程中的一项关键技术。有限元方法及计算机技术的发展为研究它的成型过程及参数优化提供帮助,降低了研究成本。
为了更好的了解自冲铆接头成型过程及对过程参数进行优化,本论文首先用数值方法及实验方法研究了自冲铆接头的成型过程。用动力学软件LS-DYNA基于Cowper-Symonds材料模型建立了2D轴对称模型,用Lagrange方法及r-自适应网格划分技术模拟了整个成型过程。结合实验的力-位移曲线及接头剖面图验证了模拟的合理性。分析了摩擦系数、过程成型时间、塑性应变比、自适应网格划分时间间隔等参数对成型的影响,摩擦系数直接影响自冲铆成型的质量。
用ANSYS有限元软件对不同弹性模量与不同泊松比的组合及不同弹性模量与不同密度组合的情况进行了模态分析。研究了单搭自冲铆接头的自由振动情况,发现泊松比对单搭自冲铆接头的固有频率几乎没有影响；自冲铆接头的固有频率随着弹性模量的增加而增加,随着密度的增加而减小。
在模态分析的基础上分析了自冲铆接头在外载荷激励下的响应状况及在冲击载荷下的瞬态性能。
最后研究了自冲铆接头及自冲铆-粘复合接头的拉伸剪切试验,研究了其承载能力及破坏方式。从实验结果来看主要有两种破坏方式：铆头从下板中拉出及下板断裂。
本文主要目的是实现自冲铆过程数值模拟及研究自冲铆接头动力学性能,为更深一步的研究提供基础。
The Self piercing riveting (SPR) is a cold forming process, in which a semi-tubular rivet pressed by a punch pierces the upper sheet and flares in the bottom sheet, and creates a strong mechanical interlock between two or more sheets. Although SPR is a new sheet material joining technique, its mechanical behaviour is better than traditional spot weld technique, SPR has been using widely in automobile industry and catch more attention from many other industrial fields. The SPR can be called the next generation joining technology and used as the a key technique in the automobile light weight. Finite element method (FEM) and computer development do a great favor of the study of SPR and its optimization of the parameters and make the cost of study down.
In order to understand the process of SPR better and optimize the parameters of the process, the SPR process was studied numerically and experimentally firstly in this thesis. A 2D axisymmetric model was generated based on Cowper-Symonds material model in LS-DYNA FEM software, Lagrange method and r-adaptivity method was employed during the simulation process. According to the force-displacement curve and the cross-section of SPR joint, it can be seen that it can be seen that the simulation results were in good agreement with the experimental results. The parameters of friction, forming time, plastic strain to failure and Time interval between adaptive refinements was studied, it can conclude that the quality of SPR is affected directly by friction.
Dynamic behavior of SPR joints of different Yong's modulus versus Passion's ratio and different Yong's modulus versus density was studied using ANSYS code. It could be found that the natural frequencies of SPR joint change slightly with the Passion's ratio varying, but increase as the Yong's modulus of sheets increase, decrease as the density of sheet increase.
The response with the inspired load and the transient behavior of SPR joint was studied based on the modal analysis.
The tensile experiments of the SPR joint and SPR-Adhesives hybrid joint were conducted in order to get the tensile capacity and failure models. It is observed that there are two main failure modes:rivet pulled out of bottom sheet and bottom sheet fracture.
This thesis aims to achieve the simulation of SPR process and studies the dynamic behavior of SPR joint and as a basis for further research.
为了更好的了解自冲铆接头成型过程及对过程参数进行优化,本论文首先用数值方法及实验方法研究了自冲铆接头的成型过程。用动力学软件LS-DYNA基于Cowper-Symonds材料模型建立了2D轴对称模型,用Lagrange方法及r-自适应网格划分技术模拟了整个成型过程。结合实验的力-位移曲线及接头剖面图验证了模拟的合理性。分析了摩擦系数、过程成型时间、塑性应变比、自适应网格划分时间间隔等参数对成型的影响,摩擦系数直接影响自冲铆成型的质量。
用ANSYS有限元软件对不同弹性模量与不同泊松比的组合及不同弹性模量与不同密度组合的情况进行了模态分析。研究了单搭自冲铆接头的自由振动情况,发现泊松比对单搭自冲铆接头的固有频率几乎没有影响；自冲铆接头的固有频率随着弹性模量的增加而增加,随着密度的增加而减小。
在模态分析的基础上分析了自冲铆接头在外载荷激励下的响应状况及在冲击载荷下的瞬态性能。
最后研究了自冲铆接头及自冲铆-粘复合接头的拉伸剪切试验,研究了其承载能力及破坏方式。从实验结果来看主要有两种破坏方式：铆头从下板中拉出及下板断裂。
本文主要目的是实现自冲铆过程数值模拟及研究自冲铆接头动力学性能,为更深一步的研究提供基础。
The Self piercing riveting (SPR) is a cold forming process, in which a semi-tubular rivet pressed by a punch pierces the upper sheet and flares in the bottom sheet, and creates a strong mechanical interlock between two or more sheets. Although SPR is a new sheet material joining technique, its mechanical behaviour is better than traditional spot weld technique, SPR has been using widely in automobile industry and catch more attention from many other industrial fields. The SPR can be called the next generation joining technology and used as the a key technique in the automobile light weight. Finite element method (FEM) and computer development do a great favor of the study of SPR and its optimization of the parameters and make the cost of study down.
In order to understand the process of SPR better and optimize the parameters of the process, the SPR process was studied numerically and experimentally firstly in this thesis. A 2D axisymmetric model was generated based on Cowper-Symonds material model in LS-DYNA FEM software, Lagrange method and r-adaptivity method was employed during the simulation process. According to the force-displacement curve and the cross-section of SPR joint, it can be seen that it can be seen that the simulation results were in good agreement with the experimental results. The parameters of friction, forming time, plastic strain to failure and Time interval between adaptive refinements was studied, it can conclude that the quality of SPR is affected directly by friction.
Dynamic behavior of SPR joints of different Yong's modulus versus Passion's ratio and different Yong's modulus versus density was studied using ANSYS code. It could be found that the natural frequencies of SPR joint change slightly with the Passion's ratio varying, but increase as the Yong's modulus of sheets increase, decrease as the density of sheet increase.
The response with the inspired load and the transient behavior of SPR joint was studied based on the modal analysis.
The tensile experiments of the SPR joint and SPR-Adhesives hybrid joint were conducted in order to get the tensile capacity and failure models. It is observed that there are two main failure modes:rivet pulled out of bottom sheet and bottom sheet fracture.
This thesis aims to achieve the simulation of SPR process and studies the dynamic behavior of SPR joint and as a basis for further research.
引文
[1]C.G Pichin, K. Young, I. Tuersley. Joining of lightweight sandwich sheets to aluminum using self-pierce riveting. Materials & Design,2007,28:2361-2365
[2]刘瑞军,李双义,张连洪等.自冲铆接技术在汽车车身轻量化中的应用.材料工艺设备,2004,11：33-36
[3]Xiaocong He, Ian Pearson, Ken Young. Self-pierce riveting for sheet materials:State of the art. Journal of Materials Processing Technology,2008,199:27-36
[4]Wayne. Cai, P. C.Wang, Wu Yang. Assembly dimensional prediction for self-piercing riveted aluminum panels[J]. International Journal of Machine Tools & Manufacture, 2005,21(45):695-704
[5]黄志超.板料连接技术进展.锻压技术,2006,4：119-122
[6]Juha Varis. Economics of clinched joint compared to riveted joint and example of applying calculations to a volume product. Journal of Materials Processing Technology, 2006,172 (1):130-138
[7]姜鸿澎.自冲铆连接增加结合点的疲劳寿命.重型汽车,2003,2：21-22
[8]Hans Horning,章洪涛译.车身用高强度汽车薄板钢连接技术的经验.汽车车身工程的材料概念,96-112
[9]R. Porcaro, A. G. Hanssen, M. Langseth, et al. Self-piercing riveting process:An experimental and numerical investigation. Journal of Materials Processing Technology, 2006,171:10-20
[10]P. Porcaro, A. G. Hanssen, M. Langseth, et al. The behavior of a self-piercing riveted connection under quasi-static loading conditions. International Journal of Solids and Structures,2006,43:5110-5131
[11]A. G. Hanssen, L. Olovsson, R. Porcaro, et al. A large-scale finite element point-connector model for self-piercing rivet connections. European Journal of Mechanics S/Solids,2010,29:484-495
[12]Y. Abe, T. Kato, K. Mori. Self-piercing riveting of high tensile strength steel and aluminum alloy sheets using conventional rivet and die. Journal of Materials Processing Technology,2008,209:3914-3922
[13]P. O. Boucharda, T. Laurenta, L. Tollier. Numerical modeling of self-pierce riveting—from riveting process modeling down to structural analysis. Journal of Materials Processing Technology,2008,202:290-300
[14]G. Casalino, A. Rotondo, A. Ludovico. On the numerical modeling of the multiphysics self piercing riveting process based on the finite element technique. Advances in Engineering Software,2008,39:787-795
[15]Xiaocong He, Biao Dong, Xunzhi Zhu. Free Vibration Characteristics of Hybrid SPR Beams. AIP Conference Proceedings,2009,1233:678-683
[16]L. Han, K.W. Young, A. Chrysanthou, et al. The effect of pre-straining on the mechanical behavior of self-piercing riveted aluminum alloy sheets. Materials and Design,2006,27:1108-1113
[17]C. G Pickin, K. Young, I. Tuersley. Joining of lightweight sandwich sheets to aluminum using self-pierce riveting. Materials and Design,2007,28:2361-2365
[18]L. Han, A. Chrysanthou, J. M. O'Sullivan. Fretting behavior of self-piercing riveted aluminum alloy joints under different interfacial conditions. Materials and Design, 2006,27:200-208
[19]L. Han, A. Chrysanthou, K.W. Young. Mechanical behavior of self-piercing riveted multi-layer joints under different specimen configurations. Materials and Design,2007, 28:2024-2033
[20]R. Porcaro, M. Langseth, A.G Hanssen, et al. Crashworthiness of self-piercing connections. International Journal of Impact Engineering,2008,35:1251-1266
[21]L. Han, A. Chrysanthou. Evaluation of quality and behaveiour of self-piercing riveted aluminum to high strength low alloy sheets with different surface coatings. Materials and Design,2008,29:458-468
[22]Y.K. Chen, L. Han, A. Chrysanthou, et al. Fretting wear in self-piercing riveted aluminum alloy sheet. Wear,2003,255:1463-1470
[23]L. Han, K.W. Young, A. Chrysanthou, et al. The effect of pre-straining on the mechanical behavior of self-piercing riveted aluminium alloy sheets. Materials and Design,2006,27:1108-1113
[24]Maofeng Fu, P. K. Mallick. Fatigue of self-piercing riveted joints in aluminum alloy 6111. International Journal of Fatigue,2003,25:183-189
[25]N.-H. Hoang, R. Porcaro, M. Langseth, et al. Self-piercing riveting connections using aluminum rivets. International Journal of Solids and Structures,2010,47:427-439
[26]P. Johnson, J. D. Cullen, L. Sharples, et al. Online visual measurement of self-pierce riveting systems to help determine the quality of the mechanical interlock. Measurement,2009,42:661-667
[27]K. Iyer, S. J. Hu, F. L. Brittman, et al. Fatigue of single-and double-rivet self-piercing riveted lap joints. Fatigue & Fracture of Engineering Materials & Structures,2005, 11(28)：997-1007
[28]黄志超,姜宁,王建忠.实心铆钉自冲铆接过程的数值模拟及其参数优化.锻压技术,2009,34(3)：156-161
[29]黄志超,占金青,陈.半空心铆钉自冲铆接工艺过程的数值模拟.锻压技术,2007,32(5)：54-58
[30]岁波,都东,常宝华等.铝合金自冲铆连接过程的模拟分析.材料科学与工艺,2007,15(5)：713-717
[31]万淑敏,胡仕新,张连洪等.模具工艺参数对自冲铆接工艺过程及铆接质量的影响.机械设计,2008,25(4)：61-65
[32]刘秀全,张连红,李双义等.自冲铆接工艺过程的有限元数值模拟.汽车技术,2006,(12)：42-45
[33]李晓静,李双义,张连洪等.半空心铆钉自冲铆连接工艺的实验研究.汽车技术,2004,(5)：21-24
[34]万淑敏,S. Jack Hu,李双义等.半空心自冲铆接的工艺参数及铆接质量判定.天津大学学报,2007,40(4)：494-498
[35]陈兴茂,黄志超,康少伟.自冲铆接疲劳强度的研究概况.华东交通大学学报,2008,25(3)：106-110
[36]刘瑞军,于胜武,朱翠娟,王永成.自冲铆接工艺参数权重分析,材料工艺设备,2007,(7)：49-51
[37]刘瑞军.半空心自冲铆接机的研究与设计,[硕士学位论文].天津：天津大学,2005
[38]赵海鸥.LS-DYNA动力学分析指南.北京：兵器工业出版社,2003
[39]曾攀.有限元分析及应用.北京：清华大学出版社,2004
[40]Daryl, L. Logan著,伍义生,吴永礼等译.有限元方法基础教程(第三版),北京：电子工业出版社,2003
[41]John O.Hanllquist. Ls-dyna Theory Manual.2005
[42]LS-DYNA Keyword User's Manual.2007, V971
[43]Singiresu S. Rao著,李欣业,张明路编译.机械振动(第四版),北京清华大学出版社,2009
[44]Xiaocong He, Wenbin Zhang, Biao Dong, et al. Free Vibration Charateristics of Clinched Joints. World Congress on Engineering,2009,2:1724-1729
[45]BOLLHOFF Technical Document/Part Ⅰ Operating-and maintenance instruction RIVET Self pierce riveting system, Varo-Tape Feed,2009
[46]Chergui, A. Beitrag zur ermudungsgerechten auslegung stanzgenieteter aluminium-leichbaukonstruktionen. (PhD Thesis), France:University of Paderborn,2004
[2]刘瑞军,李双义,张连洪等.自冲铆接技术在汽车车身轻量化中的应用.材料工艺设备,2004,11：33-36
[3]Xiaocong He, Ian Pearson, Ken Young. Self-pierce riveting for sheet materials:State of the art. Journal of Materials Processing Technology,2008,199:27-36
[4]Wayne. Cai, P. C.Wang, Wu Yang. Assembly dimensional prediction for self-piercing riveted aluminum panels[J]. International Journal of Machine Tools & Manufacture, 2005,21(45):695-704
[5]黄志超.板料连接技术进展.锻压技术,2006,4：119-122
[6]Juha Varis. Economics of clinched joint compared to riveted joint and example of applying calculations to a volume product. Journal of Materials Processing Technology, 2006,172 (1):130-138
[7]姜鸿澎.自冲铆连接增加结合点的疲劳寿命.重型汽车,2003,2：21-22
[8]Hans Horning,章洪涛译.车身用高强度汽车薄板钢连接技术的经验.汽车车身工程的材料概念,96-112
[9]R. Porcaro, A. G. Hanssen, M. Langseth, et al. Self-piercing riveting process:An experimental and numerical investigation. Journal of Materials Processing Technology, 2006,171:10-20
[10]P. Porcaro, A. G. Hanssen, M. Langseth, et al. The behavior of a self-piercing riveted connection under quasi-static loading conditions. International Journal of Solids and Structures,2006,43:5110-5131
[11]A. G. Hanssen, L. Olovsson, R. Porcaro, et al. A large-scale finite element point-connector model for self-piercing rivet connections. European Journal of Mechanics S/Solids,2010,29:484-495
[12]Y. Abe, T. Kato, K. Mori. Self-piercing riveting of high tensile strength steel and aluminum alloy sheets using conventional rivet and die. Journal of Materials Processing Technology,2008,209:3914-3922
[13]P. O. Boucharda, T. Laurenta, L. Tollier. Numerical modeling of self-pierce riveting—from riveting process modeling down to structural analysis. Journal of Materials Processing Technology,2008,202:290-300
[14]G. Casalino, A. Rotondo, A. Ludovico. On the numerical modeling of the multiphysics self piercing riveting process based on the finite element technique. Advances in Engineering Software,2008,39:787-795
[15]Xiaocong He, Biao Dong, Xunzhi Zhu. Free Vibration Characteristics of Hybrid SPR Beams. AIP Conference Proceedings,2009,1233:678-683
[16]L. Han, K.W. Young, A. Chrysanthou, et al. The effect of pre-straining on the mechanical behavior of self-piercing riveted aluminum alloy sheets. Materials and Design,2006,27:1108-1113
[17]C. G Pickin, K. Young, I. Tuersley. Joining of lightweight sandwich sheets to aluminum using self-pierce riveting. Materials and Design,2007,28:2361-2365
[18]L. Han, A. Chrysanthou, J. M. O'Sullivan. Fretting behavior of self-piercing riveted aluminum alloy joints under different interfacial conditions. Materials and Design, 2006,27:200-208
[19]L. Han, A. Chrysanthou, K.W. Young. Mechanical behavior of self-piercing riveted multi-layer joints under different specimen configurations. Materials and Design,2007, 28:2024-2033
[20]R. Porcaro, M. Langseth, A.G Hanssen, et al. Crashworthiness of self-piercing connections. International Journal of Impact Engineering,2008,35:1251-1266
[21]L. Han, A. Chrysanthou. Evaluation of quality and behaveiour of self-piercing riveted aluminum to high strength low alloy sheets with different surface coatings. Materials and Design,2008,29:458-468
[22]Y.K. Chen, L. Han, A. Chrysanthou, et al. Fretting wear in self-piercing riveted aluminum alloy sheet. Wear,2003,255:1463-1470
[23]L. Han, K.W. Young, A. Chrysanthou, et al. The effect of pre-straining on the mechanical behavior of self-piercing riveted aluminium alloy sheets. Materials and Design,2006,27:1108-1113
[24]Maofeng Fu, P. K. Mallick. Fatigue of self-piercing riveted joints in aluminum alloy 6111. International Journal of Fatigue,2003,25:183-189
[25]N.-H. Hoang, R. Porcaro, M. Langseth, et al. Self-piercing riveting connections using aluminum rivets. International Journal of Solids and Structures,2010,47:427-439
[26]P. Johnson, J. D. Cullen, L. Sharples, et al. Online visual measurement of self-pierce riveting systems to help determine the quality of the mechanical interlock. Measurement,2009,42:661-667
[27]K. Iyer, S. J. Hu, F. L. Brittman, et al. Fatigue of single-and double-rivet self-piercing riveted lap joints. Fatigue & Fracture of Engineering Materials & Structures,2005, 11(28)：997-1007
[28]黄志超,姜宁,王建忠.实心铆钉自冲铆接过程的数值模拟及其参数优化.锻压技术,2009,34(3)：156-161
[29]黄志超,占金青,陈.半空心铆钉自冲铆接工艺过程的数值模拟.锻压技术,2007,32(5)：54-58
[30]岁波,都东,常宝华等.铝合金自冲铆连接过程的模拟分析.材料科学与工艺,2007,15(5)：713-717
[31]万淑敏,胡仕新,张连洪等.模具工艺参数对自冲铆接工艺过程及铆接质量的影响.机械设计,2008,25(4)：61-65
[32]刘秀全,张连红,李双义等.自冲铆接工艺过程的有限元数值模拟.汽车技术,2006,(12)：42-45
[33]李晓静,李双义,张连洪等.半空心铆钉自冲铆连接工艺的实验研究.汽车技术,2004,(5)：21-24
[34]万淑敏,S. Jack Hu,李双义等.半空心自冲铆接的工艺参数及铆接质量判定.天津大学学报,2007,40(4)：494-498
[35]陈兴茂,黄志超,康少伟.自冲铆接疲劳强度的研究概况.华东交通大学学报,2008,25(3)：106-110
[36]刘瑞军,于胜武,朱翠娟,王永成.自冲铆接工艺参数权重分析,材料工艺设备,2007,(7)：49-51
[37]刘瑞军.半空心自冲铆接机的研究与设计,[硕士学位论文].天津：天津大学,2005
[38]赵海鸥.LS-DYNA动力学分析指南.北京：兵器工业出版社,2003
[39]曾攀.有限元分析及应用.北京：清华大学出版社,2004
[40]Daryl, L. Logan著,伍义生,吴永礼等译.有限元方法基础教程(第三版),北京：电子工业出版社,2003
[41]John O.Hanllquist. Ls-dyna Theory Manual.2005
[42]LS-DYNA Keyword User's Manual.2007, V971
[43]Singiresu S. Rao著,李欣业,张明路编译.机械振动(第四版),北京清华大学出版社,2009
[44]Xiaocong He, Wenbin Zhang, Biao Dong, et al. Free Vibration Charateristics of Clinched Joints. World Congress on Engineering,2009,2:1724-1729
[45]BOLLHOFF Technical Document/Part Ⅰ Operating-and maintenance instruction RIVET Self pierce riveting system, Varo-Tape Feed,2009
[46]Chergui, A. Beitrag zur ermudungsgerechten auslegung stanzgenieteter aluminium-leichbaukonstruktionen. (PhD Thesis), France:University of Paderborn,2004