干式双离合器模块优化设计方法
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摘要
论文结合国家“863”项目——经济型轿车高性能自动变速器技术开发,以已经设计的干式双离合器模块为研究对象,系统的进行了先参数校核,再有限元分析,最后拓扑优化的研究。
本论文的主要内容包括:
(1)根据发动机参数信息和整车传动系基本参数,对干式膜片弹簧双离合器中摩擦片、压盘以及膜片弹簧等零部件的基本参数进行了校核;
(2)利用有限单元法基本理论,借助Pro/E、ANSYS软件针对开发设计的干式双离合器模块中的飞轮、中间飞轮及离合器Ⅰ的部分结构(离合器盖Ⅰ、压盘Ⅰ)建立有限元模型,并进行有限元仿真分析,以此评价结构设计的合理性。
(3)基于有限元法仿真分析结果,探索利用连续体结构的拓扑优化方法,以结构最小应变能为目标,分别对上述结构进行了拓扑优化分析。并通过对比优化前后结构的仿真结果,验证优化方法的合理性、可行性。
证明了优化后结构材料分布的更为合理,在减轻结构质量的同时也降低和均匀化了结构应力,从而证实了连续体拓扑优化设计的方法在结构减重方面的可行性。
干式双离合器模块优化方法的探索,为产品的开发设计提供了理论参考依据,同时也为缩短干式双离合器系统开发周期奠定了基础。工作内容对干式双离合器模块的改进及DCT系统的开发设计提供有意义的参考价值。
The automatization of transmission system speed change has always been the goal people pursue constantly. As the need of market to automobile equipped with automatic transmission increases rapidly, the application of automatic transmission of automobile has much more important practical significance. Nowadays, the automatic transmission of automobile in the market mainly are AT, CVT and AMT which has been being researched with great efforts at home and abroad in recent years.
Although AMT has retained high transmission efficiency, low price, easy to manufacture and other advantages of MT, its working principle decides the production of power transmission interruption in the process of gear change, which will definitely produce the impact of power transmission system. Compared with AT, the interruption of AMT power transmission makes the shift quality of automobile relatively bad, which will have certain influence to automobile’s smoothness, power, comfort, economical efficiency and release of fuel oil and acceleration performance. AT can make automobile start placidly and make acceleration equably and softly, but traditional AT structure is comparatively complex and the manufacture cost is relatively high. Therefore, pursuing the automatic transmission which can not only sufficiently use the advantages of high transmission efficiency and good production inheritance of MT, but also realize not to interrupt power shift and have comparatively good smoothness become the topic concerned by automobile industry in the globe. Hence, a kind of automatic transmission adopting double-clutch structure (DCT) come into existence as the situation requires.
It is generally recognized that DCT is an upgrading product of AMT. It integrates the advantages of MT, AMT, AT and other transmissions and improves the vehicle performance greatly; in addition, it has a low cost and broad application. However, as one of important parts of DCT system, double-clutch module is a kind of new clutch form, so there are still some technical problems which need to be improved. To China, which is the third big production country of automobile in the world, the deep research and product of it will definitely have positive significance to improve our independent development ability of automatic transmission and the position of big automobile country.
There are two kinds of double-clutch used in DCT, dry and wet. Taking dry double-clutch as the research object, on the basis of double-clutch design module made by former researchers and taking theory analysis as the foundation, the thesis checks the basic parameters of dry double clutch again and makes the research of simulated finite element analysis through leading the physical model of flywheel, middle flywheel, clutch cover I and plate I into ANSYS by Pro/E software with seamless link technology. The thesis analyses the calculated result carefully, evaluates the reasonability of initial design of structure, finally proposes the improvement plan and makes optimization design to the parts using Topological Optimization module of ANSYS software and combining with actual situations. The main works of the thesis are as follows:
(1) Introduce production, development and advantages of double-clutch automatic transmission, analyze the research and development significance of double-clutch automatic transmission and the problems of structure that will be met during the development process, and then introduce the main research contents of this thesis.
(2) According to parameter information of engine and basic parameters of whole transmission system and combining with expected performance requirements of DCT, the thesis makes analysis of work characteristics to the designed dry double-clutch module and checks the basic parameters of frictional plate, pressure plate, diaphragm spring and other components and parts of dry diaphragm spring double-clutch. The result shows that the designed module can meet the work requirements of double-clutch automatic transmission.
(3) On the basis of work characteristics and basic parameters meeting the requirements, the thesis establishes finite element model to the partial structure of flywheel, middle flywheel and clutch I of developed and designed dry double-clutch module using the basic theory of finite unit method and relying on ANSYS software, respectively stimulates each work situation to make statics and energetics analysis on the basis of former researches and then researches on the reasonability of its structure design.
The finite element calculation shows that the analyzed structure design is accordance with design requirements. However, it is also found in the research that although the intension, rigidity, thermal stress and transfiguration of designed structure meet the design requirements, there are also situations of material waste and uneven stress distribution, so it is necessary to make weight reduction optimization design in the case of meeting structure requirements.
(4) Respectively carry out topological optimization analysis and improvement to flywheel, middle flywheel, clutch cover I and plate I basing on finite element method emulative analysis result, using topological optimization method of continuous body structure and taking the least strain energy of structure as the goal. It is proved that the structure material distribution after optimization is much more reasonable through comparing and analyzing the finite element calculation results of structure before and after optimization under the same condition, and at the same time of lightening structure quality, the structure stress is also reduced and homogenized, which proves the feasibility of topological optimization design method of continuous body in the structure weight reduction aspect.
The thesis makes finite emulation to module through analyzing work characteristics of dry double-clutch module and using ANSYS software. After making the detailed analysis to emulative result of structure, the thesis evaluates the reasonability of initial design of structure and finally exploringly proposes structure improvement plan using topological optimization module of ANSYS software. The work content provides significant reference value to the improvement of dry double-clutch module and development and design of DCT system.
本论文的主要内容包括:
(1)根据发动机参数信息和整车传动系基本参数,对干式膜片弹簧双离合器中摩擦片、压盘以及膜片弹簧等零部件的基本参数进行了校核;
(2)利用有限单元法基本理论,借助Pro/E、ANSYS软件针对开发设计的干式双离合器模块中的飞轮、中间飞轮及离合器Ⅰ的部分结构(离合器盖Ⅰ、压盘Ⅰ)建立有限元模型,并进行有限元仿真分析,以此评价结构设计的合理性。
(3)基于有限元法仿真分析结果,探索利用连续体结构的拓扑优化方法,以结构最小应变能为目标,分别对上述结构进行了拓扑优化分析。并通过对比优化前后结构的仿真结果,验证优化方法的合理性、可行性。
证明了优化后结构材料分布的更为合理,在减轻结构质量的同时也降低和均匀化了结构应力,从而证实了连续体拓扑优化设计的方法在结构减重方面的可行性。
干式双离合器模块优化方法的探索,为产品的开发设计提供了理论参考依据,同时也为缩短干式双离合器系统开发周期奠定了基础。工作内容对干式双离合器模块的改进及DCT系统的开发设计提供有意义的参考价值。
The automatization of transmission system speed change has always been the goal people pursue constantly. As the need of market to automobile equipped with automatic transmission increases rapidly, the application of automatic transmission of automobile has much more important practical significance. Nowadays, the automatic transmission of automobile in the market mainly are AT, CVT and AMT which has been being researched with great efforts at home and abroad in recent years.
Although AMT has retained high transmission efficiency, low price, easy to manufacture and other advantages of MT, its working principle decides the production of power transmission interruption in the process of gear change, which will definitely produce the impact of power transmission system. Compared with AT, the interruption of AMT power transmission makes the shift quality of automobile relatively bad, which will have certain influence to automobile’s smoothness, power, comfort, economical efficiency and release of fuel oil and acceleration performance. AT can make automobile start placidly and make acceleration equably and softly, but traditional AT structure is comparatively complex and the manufacture cost is relatively high. Therefore, pursuing the automatic transmission which can not only sufficiently use the advantages of high transmission efficiency and good production inheritance of MT, but also realize not to interrupt power shift and have comparatively good smoothness become the topic concerned by automobile industry in the globe. Hence, a kind of automatic transmission adopting double-clutch structure (DCT) come into existence as the situation requires.
It is generally recognized that DCT is an upgrading product of AMT. It integrates the advantages of MT, AMT, AT and other transmissions and improves the vehicle performance greatly; in addition, it has a low cost and broad application. However, as one of important parts of DCT system, double-clutch module is a kind of new clutch form, so there are still some technical problems which need to be improved. To China, which is the third big production country of automobile in the world, the deep research and product of it will definitely have positive significance to improve our independent development ability of automatic transmission and the position of big automobile country.
There are two kinds of double-clutch used in DCT, dry and wet. Taking dry double-clutch as the research object, on the basis of double-clutch design module made by former researchers and taking theory analysis as the foundation, the thesis checks the basic parameters of dry double clutch again and makes the research of simulated finite element analysis through leading the physical model of flywheel, middle flywheel, clutch cover I and plate I into ANSYS by Pro/E software with seamless link technology. The thesis analyses the calculated result carefully, evaluates the reasonability of initial design of structure, finally proposes the improvement plan and makes optimization design to the parts using Topological Optimization module of ANSYS software and combining with actual situations. The main works of the thesis are as follows:
(1) Introduce production, development and advantages of double-clutch automatic transmission, analyze the research and development significance of double-clutch automatic transmission and the problems of structure that will be met during the development process, and then introduce the main research contents of this thesis.
(2) According to parameter information of engine and basic parameters of whole transmission system and combining with expected performance requirements of DCT, the thesis makes analysis of work characteristics to the designed dry double-clutch module and checks the basic parameters of frictional plate, pressure plate, diaphragm spring and other components and parts of dry diaphragm spring double-clutch. The result shows that the designed module can meet the work requirements of double-clutch automatic transmission.
(3) On the basis of work characteristics and basic parameters meeting the requirements, the thesis establishes finite element model to the partial structure of flywheel, middle flywheel and clutch I of developed and designed dry double-clutch module using the basic theory of finite unit method and relying on ANSYS software, respectively stimulates each work situation to make statics and energetics analysis on the basis of former researches and then researches on the reasonability of its structure design.
The finite element calculation shows that the analyzed structure design is accordance with design requirements. However, it is also found in the research that although the intension, rigidity, thermal stress and transfiguration of designed structure meet the design requirements, there are also situations of material waste and uneven stress distribution, so it is necessary to make weight reduction optimization design in the case of meeting structure requirements.
(4) Respectively carry out topological optimization analysis and improvement to flywheel, middle flywheel, clutch cover I and plate I basing on finite element method emulative analysis result, using topological optimization method of continuous body structure and taking the least strain energy of structure as the goal. It is proved that the structure material distribution after optimization is much more reasonable through comparing and analyzing the finite element calculation results of structure before and after optimization under the same condition, and at the same time of lightening structure quality, the structure stress is also reduced and homogenized, which proves the feasibility of topological optimization design method of continuous body in the structure weight reduction aspect.
The thesis makes finite emulation to module through analyzing work characteristics of dry double-clutch module and using ANSYS software. After making the detailed analysis to emulative result of structure, the thesis evaluates the reasonability of initial design of structure and finally exploringly proposes structure improvement plan using topological optimization module of ANSYS software. The work content provides significant reference value to the improvement of dry double-clutch module and development and design of DCT system.
引文
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[2]葛安林.变速器技术的现状与展望[J].2005传动会议报告,2005年8月.
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[4]葛安林.自动变速器(四)——液力变矩器(AT)的典型结构及发展趋势(上)[J].汽车技术,2001(8).
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[6]葛安林.自动变速器(七)——无级变速器CVT(上)[J],汽车技术,2001(11).
[7]葛安林.自动变速器(八)——无级变速器CVT(下)[J],汽车技术,2001(12).
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[2]葛安林.变速器技术的现状与展望[J].2005传动会议报告,2005年8月.
[3]葛安林.自动变速器(一)——自动变速器综述[J].汽车技术,2001(5).
[4]葛安林.自动变速器(四)——液力变矩器(AT)的典型结构及发展趋势(上)[J].汽车技术,2001(8).
[5]葛安林.自动变速器(六)——电控机械式自动变速器(AMT)[J].汽车技术,2001(10).
[6]葛安林.自动变速器(七)——无级变速器CVT(上)[J],汽车技术,2001(11).
[7]葛安林.自动变速器(八)——无级变速器CVT(下)[J],汽车技术,2001(12).
[8]葛安林.自动变速器[J].汽车技术,2001-10.
[9]吴天.双离合器的设计与开发[D].上海交通大学硕士学位论文,2007.12.
[10]杨昭,双离合器自动变速器动力学建模及仿真研究[D],硕士学位论文,吉林大学,2007.
[11]牛铭奎.葛安林,等.双离合器式自动变速器简介[J].汽车工艺与材料,2002.12.
[12]葛安林.中国自动变速器的发展[J].中日汽车高峰论坛.2008.12.
[13]张毅,潘可耕,等.离合器及机械变速[M].北京:化学工业出版社.2005.17-20.
[14]王望予.汽车设计[M].机械工业出版社.2005年.39-40.
[15]姚晓涛.双离合器自动变速器系统性能研究[D].重庆大学硕士论文,2006.(6).
[16]雷雨龙,邓云飞,张建国,王健,宋德臣,等.应用于干式双离合器上的两个飞轮[P]:中国,200810050338. 2008-01-29.
[17]马讯,过学讯,赵幼平,阂晓炜.基于有限元法的结构优化与灵敏度分析[J].机械科学与技术,Vol.21,No.4,2002.7.
[18]Peter Kohnke, Ph.D. ANSYS, Inc. Theory Release 5.7. ANSYS, Inc. Southpointe.
[19]H.Flegl,R.Wuest,N.Stelter,I.Szodfridt.Das Porsche-Doppel Kupplungs (PDK-)Getriebe[J].ATZ Automobil Technical.1987.89(9).
[20]唐德江.双离合器自动变速器的研究[D].长春:吉林大学汽车学院,2005.
[21]余俊.现代设计方法及应用[M].北京:中国标准出版社,2002.2
[22]梁新华,朱平,林忠钦,何俊,张彦.有限元法与试验法相结合进行客车车架结构分析[J],机械设计与研究.Vol.20,No.6,2004.10.
[23]ANSYS, Inc. ANSYS Commands Reference. Ninth Edition. SAS. IP Inc,1997:41-78.
[24]Robert A. E, Weinstock, Philip T. Krein; Robert A. White.Optimal Sizing and Selection of Hybrid Electric Vehicle Coments.IEEE.1993:251-25.
[25]ANSYS, Inc. ANSYS Element Reference.Ninth Edition.SAS,IP Inc 1997:2135.
[26]ANSYS Release 9.0 Documentation. ANSYS. Inc. 2004.
[27]杨萍,贺小明. ANSYS与Pro/E间无缝连接的应用研究[J].机械设计与制造,2006.1.
[28]谭继锦.汽车有限元法[M].人民交通出版社.2005.1.
[29]陈茹雯.浅谈拓扑优化[J].机电信息,2004,9.
[30]孙焕纯,柴山,王跃方.离散变量结构优化设计[M].大连理工大学出版社,1995.
[31]李国深,M.耶纳.塑性大应变微结构力学[M].科学出版社,1993.
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