面向整车开发的冲压与注塑同步工程分析与研究
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摘要
汽车制造企业之间的竞争日趋激烈,要想赢得竞争,就要以市场为中心,以最快速度响应多变的市场,提高汽车企业的竞争力并迅速赢得市场与用户。同步工程方法(SE)是缩短产品开发周期的有效措施之一
同步工程(Simultaneous Engineering)是集成地、并行地设计产品及其零部件和相关各种过程的一种系统方法。汽车开发是一个研发周期长、成本投入大、参与人员与部门多的工作行为,同步考虑工艺、质量等综合设计元素,需要先进的计算机辅助技术来实现各种工程分析。
通过与国内知名合资汽车设计公司及供应商在整个汽车项目开发期间的合作,论述了整车的开发流程,及各个阶段同步工程的实施方案；介绍了同步工程方法在整车开发中的核心技术手段,并提出了在国内汽车研发企业实施同步工程的发展方向。
对同步工程在整车开发中的关键技术进行了深入研究,包括冲压与注塑两个关系产品制造成败的重要方面。从力学模型和方法理论,到制造过程可能出现的成形缺陷,以及CAE在冲压与注塑工艺中的预测及指导作用进行——论述。
最后,从同步工程的核心技术,板料冲压成形分析及注塑成形分析在整车开发中的应用,特别是在造型设计、结构设计及试制三阶段作了重点论述。通过经验丰富的工艺人员及模具供应商的参与,对设计提出合理化建议,并以侧围外板及仪表板中间嵌饰板为例,建立了有限元分析模型,通过使用AutoForm及MoldFlow软件进行分析,用分析结果指导结构设计,进行更改。非常明确的表明了冲压成形及注塑成形分析技术对车身设计的重要性,对后期的模具开发的重要性。
Automotive industry increasingly fierce competition among enterprises, in order to win the competition, we must take the market as the center, the fastest to respond to market changes, and quickly win market and customers. Simultaneous engineering (SE) is one of effective measures to shorten product development cycle.
Simultaneous Engineering is integrated, the parallel design of products and their components and related processes in a systematic way. Vehicle development is a long cycle, high investment, many participants with the department's work behavior, synchronously to account for process, quality and design elements, requiring advanced computer-aided techniques to achieve all kinds of simulations.
Cooperated with the famous car design company and mold suppliers during the entire project development, this paper discusses the vehicle development process and the various stages of the implementation of simultaneous engineering program, introduces the core technical means of simultaneous engineering approach in the vehicle development, and proposes research and development enterprises in the domestic automobile how to develop projects simultaneously.
Deeply research on the key technologies of Simultaneous Engineering in the vehicle development, including two important aspects as stamping and injection which make great influence on mold manufacture. This paper discuss the mechanical model and methods, forming defects which may occur in the manufacturing process and the prediction and guidance of CAE in the stamping and injection mold manufacture.
Finally, the core technology of simultaneous engineering, sheet metal stamping and plastic injection molding analysis are discussed in the vehicle development, particularly in the modeling design, structural design and trial three stages. Experienced personnel and mold supplier make rationalization proposal for design. We have done analysis on body-side outer panel and instrument panel trim insert, establish finite element model by using the AutoForm and MoldFlow software. The results of analysis guide structural design changes. It's clear that the stamping and plastic injection molding analysis are important to body design and mold development.
同步工程(Simultaneous Engineering)是集成地、并行地设计产品及其零部件和相关各种过程的一种系统方法。汽车开发是一个研发周期长、成本投入大、参与人员与部门多的工作行为,同步考虑工艺、质量等综合设计元素,需要先进的计算机辅助技术来实现各种工程分析。
通过与国内知名合资汽车设计公司及供应商在整个汽车项目开发期间的合作,论述了整车的开发流程,及各个阶段同步工程的实施方案；介绍了同步工程方法在整车开发中的核心技术手段,并提出了在国内汽车研发企业实施同步工程的发展方向。
对同步工程在整车开发中的关键技术进行了深入研究,包括冲压与注塑两个关系产品制造成败的重要方面。从力学模型和方法理论,到制造过程可能出现的成形缺陷,以及CAE在冲压与注塑工艺中的预测及指导作用进行——论述。
最后,从同步工程的核心技术,板料冲压成形分析及注塑成形分析在整车开发中的应用,特别是在造型设计、结构设计及试制三阶段作了重点论述。通过经验丰富的工艺人员及模具供应商的参与,对设计提出合理化建议,并以侧围外板及仪表板中间嵌饰板为例,建立了有限元分析模型,通过使用AutoForm及MoldFlow软件进行分析,用分析结果指导结构设计,进行更改。非常明确的表明了冲压成形及注塑成形分析技术对车身设计的重要性,对后期的模具开发的重要性。
Automotive industry increasingly fierce competition among enterprises, in order to win the competition, we must take the market as the center, the fastest to respond to market changes, and quickly win market and customers. Simultaneous engineering (SE) is one of effective measures to shorten product development cycle.
Simultaneous Engineering is integrated, the parallel design of products and their components and related processes in a systematic way. Vehicle development is a long cycle, high investment, many participants with the department's work behavior, synchronously to account for process, quality and design elements, requiring advanced computer-aided techniques to achieve all kinds of simulations.
Cooperated with the famous car design company and mold suppliers during the entire project development, this paper discusses the vehicle development process and the various stages of the implementation of simultaneous engineering program, introduces the core technical means of simultaneous engineering approach in the vehicle development, and proposes research and development enterprises in the domestic automobile how to develop projects simultaneously.
Deeply research on the key technologies of Simultaneous Engineering in the vehicle development, including two important aspects as stamping and injection which make great influence on mold manufacture. This paper discuss the mechanical model and methods, forming defects which may occur in the manufacturing process and the prediction and guidance of CAE in the stamping and injection mold manufacture.
Finally, the core technology of simultaneous engineering, sheet metal stamping and plastic injection molding analysis are discussed in the vehicle development, particularly in the modeling design, structural design and trial three stages. Experienced personnel and mold supplier make rationalization proposal for design. We have done analysis on body-side outer panel and instrument panel trim insert, establish finite element model by using the AutoForm and MoldFlow software. The results of analysis guide structural design changes. It's clear that the stamping and plastic injection molding analysis are important to body design and mold development.
引文
[1]庄明惠,王佳怡.并行工程在汽车开发中的应用.世界标准化与质量管理,第8期：15-17.
[2]徐满年.汽车产品开发应用同步工程方法的探讨.上海汽车,2000,1：26-28.
[3]罗伯特,巴特里克.项目过程测评与管理第2版.杨磊译,电子工业出版社,2003.
[4]汪卫东.国外汽车车身开发的特点分析.上海汽车,2004,1：25-32.
[5]R. ZAMBRANO.菲亚特Punto:“同步工程”的经验.轻型汽车技术,1996,2(108)：12-25.
[6]张申生等.敏捷制造的理论.技术与实践出版社,2000.
[7]Kanet J. J, Faisst W.& Mertens P. Application of information technology to a virtual enterprise broker. The case of Bill Epstein. International Journal of Production Economics,1999
[8]唐齐千.同步工程在产品决策实施中的应用.决策借鉴,1990,2：14-15.
[9]郑蒿祥.试论同步工程在产品和过程开发中的应用.汽车研究与开发,2000,6：15-18.
[10]侯春.汽车车身产品开发试制工程技术体系.世界汽车,2003,7：57-58.
[11]王小新,于昕世,刘亚东.基于并行工程思想的模具开发与制造过程[J].模具技术,2001(5)：10-12.
[12]李建新.现代汽车车身开发关键技术及应用.机电产品开发与创新,2005,9(5)：64-66.
[13]钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用.北京理工大学出版社,1998.
[14]兰箭,董湘怀,李志刚.有限元逆算法与板料成形工艺的评价.中国机械工程,2002,13(10)：826-829.
[15]李光耀.三维板料成形过程的显式有限元分析.计算结构力学及其应用.1996,13(3)：253-267.
[16]钟志华,李光耀.板材冲压成形的计算机仿真与应用.北京：北京理工大学出版社,1998.6.
[17]Cavendish J C. Automatic triangulation of arbitrary planar domains for the finite element method. Int. J. Number Methods Eng,1974,8:679～ 696.
[18]胡世光,陈鹤峥.板料冷压成形的工程解析.北京航空航天大学出版社,2004.
[19]李东升,覆盖件计算机模拟成形中的几个关键问题.航空制造工程,1994.4
[20]彭颖红.金属塑性成形仿真技术.上海交通大学出版社,1999.
[21]Toh CH, Kobayashi S. Deformation analysis and blank design in square cup drawing. Int J Mach Tool Des Res,1985,25(1):1532.
[22]Ohwue T, Takita M. Analysis of material draw-in from flange corner during deep drawing of polygonal shells. Proceedings of the 3rd I. C. T. P, 1990,3:13～118.
[23]Makinouchi A. Sheet metal forming simulation in industry. J of Materials Processing Technology,1996,60:16～19.
[24]Keer T J, Sturt R M V. Sheet metal pressings-the integration of finite element analysis with the design process. Trans of SAE, J of Materials and Manufacturing,1991, No 910771,736～741.
[25]朱芝培.改性塑料在汽车零部件中的应用.化工新型材料,2007,3(35)：51-56.
[26]梁瑞凤.气体辅助注塑成形技术——项向传统注塑工艺挑战的未来技术[J].高分子通报,1996(12),226-233.
[27]董斌斌,苏彬,周应国等.注射成形中常见成形缺陷的研究[J].模具工业,2005(9)：31-36.
[28]隋世剑,孙在军.轿车内饰件注塑生产质量问题及解决措施.塑料工业,2005,5(33)：103-105.
[29]肖长江,刘春太,申长雨.注塑制件熔接线形成、性能和预测[J].工程塑料应用,2003,31(3)：17-20.
[30]余玲,陈忠桂.CAE技术在解决汽车内饰注塑产品缺陷中的应用.工程塑料应用,2008,36(7)：40-42.
[31]罗宇玲,曾亚森.基于MoldFlow软件的注塑产品熔接痕分析及优化设计.模具制造,2006,11：(17-19)
[32]赵涛,张海鸥.汽车内饰件熔接线缺陷CAE分析及浇注系统优化设计.电加工与模具,2007,5：39-41.
[33]涂小华,高保真MOLDFLOW在仪表板注塑成型中的应用.江西科学,2006,10(5)：350-352
[34]吴崇峰.实用注射模CAD/CAM/CAE技术[M].北京：轻工出版社,2000.
[35]程国良,谢晖,杨大宇,钟志华.汽车车身冲压模具开发同步工程的关键技术研究.模具技术,2008,1：5-9.
[36]宋放之等.现代模具制造技术.机械工业出版社,2001,1.
[37]王都,王志刚,王金山.欧美模具企业考察报告,2001,03.
[38]林华.从汽车焊装领域看同步工程的发展和应用[J].工艺与装备.2009(1).
[39]袁智军,赵晓宇,胡杰.基于同步工程的汽车车身设计同步流程分析.机电产品开发与创新.22(5).2009.
[40]李国波,储灿飞.同步工程中涂装工艺对汽车产品开发的影响.电镀与涂饰.2009(12).
[41]邹素平.板料成型CAE技术在车身设计同步工程中的应用.数字化园地.2009(6).
[42]谢贻权.弹性和塑性力学中的有限元法.北京：机械工程出版社,1981,8.
[43]徐丙坤,施法中,陈中奎.板料冲压成形数值模拟中的几个关键问题.塑性工程学报,2001,8(2)：32-35.
[2]徐满年.汽车产品开发应用同步工程方法的探讨.上海汽车,2000,1：26-28.
[3]罗伯特,巴特里克.项目过程测评与管理第2版.杨磊译,电子工业出版社,2003.
[4]汪卫东.国外汽车车身开发的特点分析.上海汽车,2004,1：25-32.
[5]R. ZAMBRANO.菲亚特Punto:“同步工程”的经验.轻型汽车技术,1996,2(108)：12-25.
[6]张申生等.敏捷制造的理论.技术与实践出版社,2000.
[7]Kanet J. J, Faisst W.& Mertens P. Application of information technology to a virtual enterprise broker. The case of Bill Epstein. International Journal of Production Economics,1999
[8]唐齐千.同步工程在产品决策实施中的应用.决策借鉴,1990,2：14-15.
[9]郑蒿祥.试论同步工程在产品和过程开发中的应用.汽车研究与开发,2000,6：15-18.
[10]侯春.汽车车身产品开发试制工程技术体系.世界汽车,2003,7：57-58.
[11]王小新,于昕世,刘亚东.基于并行工程思想的模具开发与制造过程[J].模具技术,2001(5)：10-12.
[12]李建新.现代汽车车身开发关键技术及应用.机电产品开发与创新,2005,9(5)：64-66.
[13]钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用.北京理工大学出版社,1998.
[14]兰箭,董湘怀,李志刚.有限元逆算法与板料成形工艺的评价.中国机械工程,2002,13(10)：826-829.
[15]李光耀.三维板料成形过程的显式有限元分析.计算结构力学及其应用.1996,13(3)：253-267.
[16]钟志华,李光耀.板材冲压成形的计算机仿真与应用.北京：北京理工大学出版社,1998.6.
[17]Cavendish J C. Automatic triangulation of arbitrary planar domains for the finite element method. Int. J. Number Methods Eng,1974,8:679～ 696.
[18]胡世光,陈鹤峥.板料冷压成形的工程解析.北京航空航天大学出版社,2004.
[19]李东升,覆盖件计算机模拟成形中的几个关键问题.航空制造工程,1994.4
[20]彭颖红.金属塑性成形仿真技术.上海交通大学出版社,1999.
[21]Toh CH, Kobayashi S. Deformation analysis and blank design in square cup drawing. Int J Mach Tool Des Res,1985,25(1):1532.
[22]Ohwue T, Takita M. Analysis of material draw-in from flange corner during deep drawing of polygonal shells. Proceedings of the 3rd I. C. T. P, 1990,3:13～118.
[23]Makinouchi A. Sheet metal forming simulation in industry. J of Materials Processing Technology,1996,60:16～19.
[24]Keer T J, Sturt R M V. Sheet metal pressings-the integration of finite element analysis with the design process. Trans of SAE, J of Materials and Manufacturing,1991, No 910771,736～741.
[25]朱芝培.改性塑料在汽车零部件中的应用.化工新型材料,2007,3(35)：51-56.
[26]梁瑞凤.气体辅助注塑成形技术——项向传统注塑工艺挑战的未来技术[J].高分子通报,1996(12),226-233.
[27]董斌斌,苏彬,周应国等.注射成形中常见成形缺陷的研究[J].模具工业,2005(9)：31-36.
[28]隋世剑,孙在军.轿车内饰件注塑生产质量问题及解决措施.塑料工业,2005,5(33)：103-105.
[29]肖长江,刘春太,申长雨.注塑制件熔接线形成、性能和预测[J].工程塑料应用,2003,31(3)：17-20.
[30]余玲,陈忠桂.CAE技术在解决汽车内饰注塑产品缺陷中的应用.工程塑料应用,2008,36(7)：40-42.
[31]罗宇玲,曾亚森.基于MoldFlow软件的注塑产品熔接痕分析及优化设计.模具制造,2006,11：(17-19)
[32]赵涛,张海鸥.汽车内饰件熔接线缺陷CAE分析及浇注系统优化设计.电加工与模具,2007,5：39-41.
[33]涂小华,高保真MOLDFLOW在仪表板注塑成型中的应用.江西科学,2006,10(5)：350-352
[34]吴崇峰.实用注射模CAD/CAM/CAE技术[M].北京：轻工出版社,2000.
[35]程国良,谢晖,杨大宇,钟志华.汽车车身冲压模具开发同步工程的关键技术研究.模具技术,2008,1：5-9.
[36]宋放之等.现代模具制造技术.机械工业出版社,2001,1.
[37]王都,王志刚,王金山.欧美模具企业考察报告,2001,03.
[38]林华.从汽车焊装领域看同步工程的发展和应用[J].工艺与装备.2009(1).
[39]袁智军,赵晓宇,胡杰.基于同步工程的汽车车身设计同步流程分析.机电产品开发与创新.22(5).2009.
[40]李国波,储灿飞.同步工程中涂装工艺对汽车产品开发的影响.电镀与涂饰.2009(12).
[41]邹素平.板料成型CAE技术在车身设计同步工程中的应用.数字化园地.2009(6).
[42]谢贻权.弹性和塑性力学中的有限元法.北京：机械工程出版社,1981,8.
[43]徐丙坤,施法中,陈中奎.板料冲压成形数值模拟中的几个关键问题.塑性工程学报,2001,8(2)：32-35.