覆盖件冲压方向调整算法的研究与软件开发
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摘要
大型汽车覆盖件的开发、研究已经成为工业界和学术界的研究热点,而大型汽车覆盖件开发的关键在于覆盖件模具的开发。冲压方向的确定在设计与模具冲压工艺制定中是十分关键的一步,它影响着拉深工艺补充面的设计、以至后续工序的确定。因此快速、合理地确定冲压方向,既能避免负角,方便成形,又能简化模具结构,不仅是冲压工艺数字化和模具CAE所关心的内容,而且对缩短模具制造周期,提高生产效率、降低成本有着十分重要的作用。
本文在详细研究了确定冲压方向原则的基础上,根据实际冲压工艺要求,设计了三种自动快速准确地确定冲压方向的方法,它们是平均网格方向法、最小拉深深度法以及最大宽度法,并且给出了它们详细的算法流程。计算出来的结果可以彩图的方式表示出来,用以直观地观察调整的方向是否合理。最后针对对称件这种特殊情况进行了特殊的处理。
以插件的形式开发软件,可较大地提高软件的可维护性和扩展性,进而降低软件系统开发成本,为了解决软件维护困难,用户新增需求难以满足的问题,本文详细地研究了插件技术的原理、插件的管理、插件的实现方案。
在深入研究了冲压工艺相关知识和插件技术的基础上,本文给出了基于插件技术的CAE软件开发过程,以覆盖件冲压冲压方向调整为例,进行了插件开发,并成功地将其应用到某项目中,通过几个具体运用实例验证,结果表明:基于插件技术的覆盖件确定冲压方向模块具有良好的运行效率和运行效果,对实际确定冲压方向有很大的帮助。
With the Automobile industry playing an increasingly important role in national economy, the research and development of big auto-body panel has become a hot pot in both industry and academe. The key point for big auto-body panel is the pane die. Among the stamping process design of the sheet part, the determination of stamping direction leads a crucial role. It affects the design of binder and addendum surfaces as well as the consequence of stamping processes. In that case, how to determine stamping direction quickly and reasonably, avoiding undercut area and simplifying die structures not only concerned by stamping process digitalization and CAE technology, but also performs profound significance in shortening the time of die manufacture, enhancing the efficiency of production meanwhile cutting down costs.
Firstly, according to the request of manufacturing process, the principles of the stamping direction were summarized, three methods for determining the direction have been suggested: grid average normal method, minimal draw depth method and maximal width method. The detailed arithmetic flows were also displayed. The results were analyzed and described as color pictures, which can help us adjust directions if they are not suitable. Aiming to the symmetry parts, special treatment has been performed lastly.
The software developed in the form of plug-in, the results indicate that the maintainability and expansibility can be improved markedly, so that the development cost can be reduced. To solve the difficulty of maintenance and meet the new demand of consumers, in this thesis, the principle, the management and the realization blue print of plug-in were carefully researched.
On the basis of summarizing the relative knowledge of stamping and plug-in technology, the development process of CAE software was presented, the plug-in developed by us already has been applied in some projects. After experiments and validation, the module based on plug-in technology can perform smoothly, this would be helpful for determining the stamping direction.
本文在详细研究了确定冲压方向原则的基础上,根据实际冲压工艺要求,设计了三种自动快速准确地确定冲压方向的方法,它们是平均网格方向法、最小拉深深度法以及最大宽度法,并且给出了它们详细的算法流程。计算出来的结果可以彩图的方式表示出来,用以直观地观察调整的方向是否合理。最后针对对称件这种特殊情况进行了特殊的处理。
以插件的形式开发软件,可较大地提高软件的可维护性和扩展性,进而降低软件系统开发成本,为了解决软件维护困难,用户新增需求难以满足的问题,本文详细地研究了插件技术的原理、插件的管理、插件的实现方案。
在深入研究了冲压工艺相关知识和插件技术的基础上,本文给出了基于插件技术的CAE软件开发过程,以覆盖件冲压冲压方向调整为例,进行了插件开发,并成功地将其应用到某项目中,通过几个具体运用实例验证,结果表明:基于插件技术的覆盖件确定冲压方向模块具有良好的运行效率和运行效果,对实际确定冲压方向有很大的帮助。
With the Automobile industry playing an increasingly important role in national economy, the research and development of big auto-body panel has become a hot pot in both industry and academe. The key point for big auto-body panel is the pane die. Among the stamping process design of the sheet part, the determination of stamping direction leads a crucial role. It affects the design of binder and addendum surfaces as well as the consequence of stamping processes. In that case, how to determine stamping direction quickly and reasonably, avoiding undercut area and simplifying die structures not only concerned by stamping process digitalization and CAE technology, but also performs profound significance in shortening the time of die manufacture, enhancing the efficiency of production meanwhile cutting down costs.
Firstly, according to the request of manufacturing process, the principles of the stamping direction were summarized, three methods for determining the direction have been suggested: grid average normal method, minimal draw depth method and maximal width method. The detailed arithmetic flows were also displayed. The results were analyzed and described as color pictures, which can help us adjust directions if they are not suitable. Aiming to the symmetry parts, special treatment has been performed lastly.
The software developed in the form of plug-in, the results indicate that the maintainability and expansibility can be improved markedly, so that the development cost can be reduced. To solve the difficulty of maintenance and meet the new demand of consumers, in this thesis, the principle, the management and the realization blue print of plug-in were carefully researched.
On the basis of summarizing the relative knowledge of stamping and plug-in technology, the development process of CAE software was presented, the plug-in developed by us already has been applied in some projects. After experiments and validation, the module based on plug-in technology can perform smoothly, this would be helpful for determining the stamping direction.
引文
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[12] Fuh-Kuo Chen.An analysis of draw bead restraining force in stamping process.international Journal of Machine Tools and Manufacture,1998,38:827-42.
[13] Ludovic Courvoisier etal.Analytical modeling of draw beads in sheet metal forming.journal of Materials Processing Technology, 2003:359-370.
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[21] S.I.Oh, W.T.Wu, J.P.Tang, etal.Capabilities and applications of FEM code DEFORM: The perspective of developer.Journal of Materials Processing Technology, 1991(27):25~41.
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[26]徐伟力.板料成形静力隐式弹塑性有限元数值模拟系统.哈尔滨:哈尔滨工业大学博士论文,1998.
[27]钟志华,李光耀.冲压成形CAE技术中接触摩擦计算的新方法.机械工程学报, 2001,37(2):33~37.
[28]陈军.基于模板的汽车覆盖件冲压工艺快速设计关键技术研究.天津:天津大学博士论文.
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[33]机械与汽车制造技术考察团.日本、美国汽车制造技术考察报告.工厂建设与设计,1997 (4) : 9-15.
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[36]袁智军.汽车车身覆盖件的工艺分析方法.广西机械,2000 (4):39-40.
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[38]畅国佛,李英.外曲翻边竖边展开周向尺寸的计算.模具技术, 2000 (1):65-70.
[39]现代模具技术编委会.汽车覆盖件模具设计与制造.北京:国防工业出版社,1998.
[40]崔令江.汽车覆盖件冲压成型技术.北京:机械工业出版社,2003.
[41]郑金桥,黄勇,王义林等.汽车覆盖件冲压工艺设计现状及发展趋势.塑性工程学报, 2003(6):9～14.
[42] Zhou D, Wagonera R H.Development and application of sheet-forming simulation.Jourmal of Material Processing Technology,1995,50:1-16.
[43]陈文亮.板料成形CAE分析教程.北京:机械工业出版社, 2005:33-36.
[44] T.Hook, J, Kolodziejski, M.Karim . Sheet Metal Stamping Classification System for Product/Process Design and Material Specification. SAE Special Publication, 1992(8970):7-17.
[45]朗志奎,胡平,赵玉谦等.一种改进的自动翻法线的算法.机械工程学报, 2006, 42(3):142～144.
[46]《现代模具技术》编委会.汽车覆盖件模具设计与制造.北京:国防工业出版社.1998:164-167.
[47]李靖谊,陈炳发,王静秋等.交互式计算机图形学.南京:航空工业出版社, 2000:152-153.
[48]苏剑.标准C++编程宝典.北京:电子工业出版社, 2005:426~427.
[49]吴宝海,王尚锦.三维参数曲线的离散算法.机械科学与技术, 2004,23(11):1363-1365.
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[2]钟佩思.模具先进制造技术发展趋势综述.模具制造, 2005 (3):1~4.
[3]王烨.拉延筋模型及汽车覆盖件成形工艺CAD/CAE集成系统关键技术的研究.上海:上海交通大学博士论文.2000:1-2.
[4]马玉芳.面对入世中国应如何发展汽车工业.汽车工业研究,2001 (5): 3~5.
[5]袁智军.汽车车身覆盖件的工艺分析方法.广西机械, 2000 (4): 39~40.
[6]崔令江.汽车覆盖件冲压成形技术.北京:机械工业出版社, 2003:6~7.
[7]陈文亮.板料成形CAE分析教程.北京:机械工业出版社, 2005:202~204.
[8]王平.板料成形中回弹补偿的曲面映射算法研究.南京:南京航空航天大学大学硕士论文, 2005:1~2.
[9]黄亚娟,丘宏扬,陈松茂.CAD/CAE/CAM技术在汽车覆盖件模具中的应用与发展.机电工程技术, 2004,33(5):13~15.
[10]胡平,刘海鹏,柳玉起.厚钣金件压弯翻边与回弹的数值研究.固体力学学报, 2002,23(1):72~80.
[11] M.B.Silva.Stamping of automotive components: a numerical and experimental and experimental investiongation.journal of Materials Processing Technology, 2004:155-156.
[12] Fuh-Kuo Chen.An analysis of draw bead restraining force in stamping process.international Journal of Machine Tools and Manufacture,1998,38:827-42.
[13] Ludovic Courvoisier etal.Analytical modeling of draw beads in sheet metal forming.journal of Materials Processing Technology, 2003:359-370.
[14]林忠钦.车身覆盖件冲压成形仿真.机械工业出版社, 2005:16~17.
[15] K.Bergstorm, S.Kivivuori, S.Osenius, etal.Computer aided design of a progressive die.Modeling of Metal Forming Processes, Kluwer, Dordrecht, 1988, 155~162.
[16] K.Fukuoka, K.Horiuchi.Integrated mold and die design and manufacturing system.Fujitsu Sci.Technol.J.1986, 22(5):438~450.
[17] M.J.Boyle . Interactive engineering systems design: A study for artificial intelligence applications.Artif.Intell.Eng, 1989, 49(2):58~69.
[18] G.Chryssolouris, K.Wright.Knowledge-based systems in manufacturing. Ann CIRP, 1986, 35(2):437~439.
[19] H.Darendeliler, B.Kaftanoglu . Deformation analysis of deep drawing by a finite elementmethod.Ann.CIRP, 1991(40):281~284.
[20] Mustafa A.Ahmetoglu, Gary Kinzel, Taylan Altan.Computer simulation for tool and process design in sheet forming.Journal of Materials Processing Technology, 1994(46):421~441.
[21] S.I.Oh, W.T.Wu, J.P.Tang, etal.Capabilities and applications of FEM code DEFORM: The perspective of developer.Journal of Materials Processing Technology, 1991(27):25~41.
[22]徐伟力,林忠钦,刘罡等.车身覆盖件冲压仿真的现状和发展趋势.机械工程学报, 2000,36(7):1~4.
[23] D.Ravi Kumar.Formability analysis of extra-deep drawing steel.Journal of Materials Processing Technology, 2002, 130-131:31-41.
[24] W.Thomas, T.Altan . Application of computer modeling in manufacturing of automotive stamping. Steel Res, 69(4/5), 1998, 181-187.
[25] M.Tisza.Numerical modeling and simulation in sheet metal forming.Journal of Materials Processing Technology, 2004, 151:58-62.
[26]徐伟力.板料成形静力隐式弹塑性有限元数值模拟系统.哈尔滨:哈尔滨工业大学博士论文,1998.
[27]钟志华,李光耀.冲压成形CAE技术中接触摩擦计算的新方法.机械工程学报, 2001,37(2):33~37.
[28]陈军.基于模板的汽车覆盖件冲压工艺快速设计关键技术研究.天津:天津大学博士论文.
[29]周济,高三德.汽车车身设计新方法与关键技术研究.华中理工大学学报, 1996,24 (9):56-60.
[30] (德)乌.谢费尔特,彼.瓦尔泽.未来汽车技术.北京:人民交通出版社, 1997:33-34.
[31] B. T. C h e c k, A. Y. C. Nee.Trends and Developments in the Automation of Design and Manufacture of Tools for Metal Stampings. Journal of Materials Processing Technology, 1998, 75: 240-252.
[32] Ken-Ichi Matsuno.Recent Research and Development in Metal Forming in Japan.Journal of Materials Processing technology, 1997, 4.
[33]机械与汽车制造技术考察团.日本、美国汽车制造技术考察报告.工厂建设与设计,1997 (4) : 9-15.
[34] S.Joshi, T.C.Chang.Graph-based heuristics for recognition of machined features from a 3D solid model.CAD, 1998, 20(2):58-66.
[35]侯义馨.冲压工艺与模具设计.北京:兵器工业出版社,1994:10-11.
[36]袁智军.汽车车身覆盖件的工艺分析方法.广西机械,2000 (4):39-40.
[37]郭忠新.汽车大型覆盖件模具CAD技术研究.山东:山东大学硕士论文, 2005.
[38]畅国佛,李英.外曲翻边竖边展开周向尺寸的计算.模具技术, 2000 (1):65-70.
[39]现代模具技术编委会.汽车覆盖件模具设计与制造.北京:国防工业出版社,1998.
[40]崔令江.汽车覆盖件冲压成型技术.北京:机械工业出版社,2003.
[41]郑金桥,黄勇,王义林等.汽车覆盖件冲压工艺设计现状及发展趋势.塑性工程学报, 2003(6):9～14.
[42] Zhou D, Wagonera R H.Development and application of sheet-forming simulation.Jourmal of Material Processing Technology,1995,50:1-16.
[43]陈文亮.板料成形CAE分析教程.北京:机械工业出版社, 2005:33-36.
[44] T.Hook, J, Kolodziejski, M.Karim . Sheet Metal Stamping Classification System for Product/Process Design and Material Specification. SAE Special Publication, 1992(8970):7-17.
[45]朗志奎,胡平,赵玉谦等.一种改进的自动翻法线的算法.机械工程学报, 2006, 42(3):142～144.
[46]《现代模具技术》编委会.汽车覆盖件模具设计与制造.北京:国防工业出版社.1998:164-167.
[47]李靖谊,陈炳发,王静秋等.交互式计算机图形学.南京:航空工业出版社, 2000:152-153.
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