汽车桥壳液压胀形成形规律的研究及数据库的设计
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摘要
液压胀形技术一种制造空心轻体构件的先进制造技术，用液压胀形工艺生产出的桥壳，可以满足车辆制造轻量化的要求，而且制件壁厚分布合理、强度刚度高。以往液压胀形工艺的设计一般都基于经验积累，耗费时间和资金，效率不高。本文取0.75吨载重车桥壳的1／2缩小比例试件进行液压胀形试验研究，首先对汽车桥壳模型进行了参数化设计，建立汽车桥壳三维模型库，并根据试验数据建立试验数据库，揭示液压胀形桥壳成形的内在规律。
本文在前期工作的基础上，建立并完善了液压胀形汽车桥壳数字模型库，根据试验桥壳的几何形状在UG(Unigraphics)建模环境中构造汽车桥壳的三维立体模型，利用UG为客户二次开发提供的UG／OPEN API程序设计模块、UG／OPEN MenuScript和UG／OPEN UIstyler两个辅助开发模块，运用VC++语言建立模型数据库，满足用户对汽车桥壳模型的需求。
基于大量的汽车桥壳的液压胀形试验，对试验数据进行整理汇总。运用Access数据库管理系统DBMS(DataBase Management System)结合Visual Basic编程语言，建立液压胀形汽车桥壳的试验数据库。本数据库可分为三部分：成功试件、起皱失稳试件和破裂试件。试验数据库可以清晰的表达不同种类试件的图像、几何参数、加载路径以及各种试验参量，并且能够对试验数据进行搜索、添加、修改、删除等数据管理操作。
最后根据大量的试验数据，对典型成功试件和失效试件进行理论研究分析，得到成功试件的合理加载路径、破裂与起皱失稳试件的成形判据，揭示管件在不同加载路径下的成形规律。
本文完善了汽车桥壳的三维模型库，建立了液压胀形桥壳的试验数据库，揭示管件在不同加载方案下液压成形规律，为管件的成形提供可靠的理论依据，能够指导模拟、试验以及生产。
The axle housing manufactured by hydroforming can meet the requirement of light weight in automotive making. The products are of reasonable thickness distribution, high strength and high rigidity. The hydroforming technic which based on the former experiences is inefficient and wastes time and fund. Aiming at above problems, this thesis takes 1/2 scale samples of a 0.75 t truck axle housing to hydroforming test and research. First it puts up the to the axle housing model and upbuild the axle housing model database. Second, it designs the testing database based on the testing data and then search the internal regulation of axle housing hydroforming.
This thesis carries out the hydroforming parametric design and perfects it on the base of former work. Three-dimensional model of the axle housing will be constructed according to the geometrical shape in the UG modeling system. In the VC++ system DLL will be created by the modules of UG/OPEN API、UG/OPEN MenuScript and UG/OPEN UIstyler, which are provided by UG secondary development. The axle housing model database can meet the user's requirement.
Testing data will be settled and managed according to a mass of axle housing hydroforming experiment. This thesis upbuilds the testing database of axle housing hydroforming by the use of Access DBMS and Visual Basic. The data can divided to three series: successful tubes、wrinkled tubes and cracked tubes. The database can clearly express the different tube images、parameters、loading paths and so on,as well as the data management and operation such as searching、adding、amending、deleting.
Finally, to get the right loading path and the criterion of the failed tubes, this thesis make an academic research and analysis to the typical successful and failed tubes based on testing database. Hydro forming regulation under different loading path will be showed.
This thesis perfects the axle housing model database and upbuilds the axle housing hydroforming database. Hydroforming regulation of tubes is showed under different loading path and the reliable basis is provided for it. The simulation、experiment and production would be well instructed.
本文在前期工作的基础上，建立并完善了液压胀形汽车桥壳数字模型库，根据试验桥壳的几何形状在UG(Unigraphics)建模环境中构造汽车桥壳的三维立体模型，利用UG为客户二次开发提供的UG／OPEN API程序设计模块、UG／OPEN MenuScript和UG／OPEN UIstyler两个辅助开发模块，运用VC++语言建立模型数据库，满足用户对汽车桥壳模型的需求。
基于大量的汽车桥壳的液压胀形试验，对试验数据进行整理汇总。运用Access数据库管理系统DBMS(DataBase Management System)结合Visual Basic编程语言，建立液压胀形汽车桥壳的试验数据库。本数据库可分为三部分：成功试件、起皱失稳试件和破裂试件。试验数据库可以清晰的表达不同种类试件的图像、几何参数、加载路径以及各种试验参量，并且能够对试验数据进行搜索、添加、修改、删除等数据管理操作。
最后根据大量的试验数据，对典型成功试件和失效试件进行理论研究分析，得到成功试件的合理加载路径、破裂与起皱失稳试件的成形判据，揭示管件在不同加载路径下的成形规律。
本文完善了汽车桥壳的三维模型库，建立了液压胀形桥壳的试验数据库，揭示管件在不同加载方案下液压成形规律，为管件的成形提供可靠的理论依据，能够指导模拟、试验以及生产。
The axle housing manufactured by hydroforming can meet the requirement of light weight in automotive making. The products are of reasonable thickness distribution, high strength and high rigidity. The hydroforming technic which based on the former experiences is inefficient and wastes time and fund. Aiming at above problems, this thesis takes 1/2 scale samples of a 0.75 t truck axle housing to hydroforming test and research. First it puts up the to the axle housing model and upbuild the axle housing model database. Second, it designs the testing database based on the testing data and then search the internal regulation of axle housing hydroforming.
This thesis carries out the hydroforming parametric design and perfects it on the base of former work. Three-dimensional model of the axle housing will be constructed according to the geometrical shape in the UG modeling system. In the VC++ system DLL will be created by the modules of UG/OPEN API、UG/OPEN MenuScript and UG/OPEN UIstyler, which are provided by UG secondary development. The axle housing model database can meet the user's requirement.
Testing data will be settled and managed according to a mass of axle housing hydroforming experiment. This thesis upbuilds the testing database of axle housing hydroforming by the use of Access DBMS and Visual Basic. The data can divided to three series: successful tubes、wrinkled tubes and cracked tubes. The database can clearly express the different tube images、parameters、loading paths and so on,as well as the data management and operation such as searching、adding、amending、deleting.
Finally, to get the right loading path and the criterion of the failed tubes, this thesis make an academic research and analysis to the typical successful and failed tubes based on testing database. Hydro forming regulation under different loading path will be showed.
This thesis perfects the axle housing model database and upbuilds the axle housing hydroforming database. Hydroforming regulation of tubes is showed under different loading path and the reliable basis is provided for it. The simulation、experiment and production would be well instructed.
引文
1 金荣，杨洪旗，徐金波，马亮．现在汽车产品开发与制造．中国机械工程学会成组技术员分会，上海同济同捷科技股份有限公司．第四届汽车产品全数字化设计开发技术方法与流程国际研讨会暨第二届中国国际汽车车身开发与模具制造技术研讨会，上海，2005．上海，中国机械工程学会成组技术员分会，2005：132
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4 R. Zhang, T. S. Zhang. Nodie Explosive Forming of Spherical Pressure Vesseis. J.M. Process Technol, 1994,41:341-347
5 张洪欣．汽车设计．第2版．北京：机械工业出版社，1998：146-148
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7 Terumori Ueda.Differential Gear Casting for Automobiles by Liquid. Bulge Forming Process PartⅡ. Sheet Metal Industries, 1983,60(4):48-56
8 Muammer Koc.Taylan A|tan.An Overall Review of the Tube Hydroforming Technology.Journal of Mate rials Processing Technology, 2001,108:384-393
9 S. H. Zhang. Developments in Hydroforming, Journal of materials Processing Technology, 1999, 91:236-244
10 Klaus Siegert. Markus HaEussermann.Recent Development in Hydroforming Technology. Journal of Materials Processing Technology, 2000,98:251-258
11 T.Sokolowski,K. Gerke,Evaluation of Tube Formability and Material Characteristics Hydraulic Bulge Testing of Tube. Journal of Materials Processing Technology, 2000, 98:34-40
12 Dohmann,Ch. Hartl. Hydroforming Method to Manufacture Light Weight Parts. Journal of Materials Processing Technology. 1996:669-676
13 F. Dohmann,Ch.. Hartl. Tube Hydroforming Research and Practical Application Journal of Materials Processing, Technology. 1997, 71:174-186
14 B. Carleer, G. vander Kevie,Lde Wintervan Veldhuizen. Analysis of the Effect of Material Properties on the Hydroforming Process of Tubes. Journal of Materials Processing Technology,2000,104:158-166
15 苑世剑．我国内高压成形技术现状与进展．锻压技术．2004，3：1-5
16 桂龙明，王桢．简议内高压成型技术．工艺与材料．2001，11：37-40
17 苑世剑，苗启斌，王仲仁．轿车后纵轴臂内高压成形研究．金属成形工艺．2004，22(3)：1-3
18 王连东．回转壳体正负成形理论及汽车桥壳胀形工艺的研究．[燕山大学工学博士论文]．2001：43-73
19 苑世剑，韩聪，刘刚，等．轿车副车架内高压成形．锻压技术．2004，3：41-44
20 苑世剑．内高压成形技术现状与发展趋势．金属成形工艺．2003，4(21)：32-34
21 郭成，杨连发．内补液增压式THF性能测试装置开发及实验研究．机械工程学报．2005，9：180-184
22 王连东，张涛，李礽．确定汽车桥壳液压胀形极限成形系数的初探．燕山大学学报，2001，25(3)：205-208
23 王连东，刘助柏，李礽．汽车桥壳复合液压胀形成形系数研究及力参量匹配．塑性工程学报，2001，8(3)：59-62
24 王连东．刘助柏．汽车桥壳液压胀形环向小圆角成形的研究．塑性工程学报，2001，8(4)：36-39
25 王连东，梁辰，李文平，等．液压胀形汽车桥壳成形理论及其试验研究．农业机械学报，2003，34(1)：124-203
26 白木，子荫．全数字化技术及其在汽车行业的应用．装备机械，2003(3)：26-27
27 任卫群，张云清，王书亭．数字化设计在汽车零部件开发中的应用．湖北汽车，2003(3)：20-24
28 求是科技．visual basic 6.0数据库开发技术与工程实践．人民邮电出版社，2004，1：1-64
29 吴绪略，曹强，曲秀丽．浅述数据库的现状与未来．山东电子2001，1：3-5
30 求是科技．visual C++什数据库开发技术与工程实践．人民邮电出版，2004，1：1-15
31 张应中，罗晓芳．基于技术的UG/Open API参数化标准件库的开发．计算机工程，2003，29(21)：180-181
32 张秀萍，孙文磊．基于UG的三维标准件库的建立方法．新疆大学学报(自然科学版)，2004，21(1)：84-56
33 于昂，张益华．UG界面开发技术在汽车模具设计中的应用．机械丁程与自动化，2005 (1):29-31
34 Geoffrey W. Rowe. Principles of Industrial Metalworking Process. Edward Arnold (Publishers)Ltd, 1977:156-159
35 张冶，洪雪，张泽帮．Unigraphics NX参数化设计实例教程．北京．清华大学出版社．2003，8：334-349
36 曾向阳．基于UG的装配用三维标准件图库的开发[C]．北京：机械工业出版社，1999
37 姚建国．制造业信息化工程的关键技术及应用[A]．北京：机械工业出版社，1999
38 施伯乐，潘锦平，何守才．数据库设计．上海交通大学出社．1989，2：1-5
39 张力科．visual basic 6.0数据库开发技术与工程实践．人民邮电出版社，2004，1：16-120
40 范国平，陈小鹏．Access2002数据库系统开发实例导航．人民邮电出版社．2002，1：1-12
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44 F Dohmann,C. Hartl.Tube hydroforming:research and practical application. Journal of Materials Processing Technology, 1997,71:174-186
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48 王小松，苑世剑，王仲仁．内高压成形起皱行为的研究．金属学报，2003．12：1276-1280
49 Altan T, Jirathearant S,Strano M,Shr S G.In:Siggert Ked,Inter Confon Hydroforrning,Fellbach Germany,2001 ;11:363
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51 Z.C. Xia. Failure analysis of tubular hydroforming. Journal of Engineering Materials and Technology, 2001(123):423-429
52 M. Sr inivasan,J. R.Shaw, K. T hompson. Tubular Hydroforming. Conelation of Experirmental and Simulation Results. SAE Technical Paper No. 980448,1998
53 F. Vollertsen. Accuracy Process Chain Using Hydroforming. Journal of Experimental and Simulation Results. SAE Technical Paper No. 980448,1998
54 张庆，周磊，赵长财，仇平．复合管胀形成形极限研究．中国机械工程，2002，9：1455-1458
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56 王小松．内高压成形过程起皱行为研究．[哈尔滨工业大学工学硕士论文]．2005，6：55-73
57 黄小仁．瓶状空心件内高压成形研究．[硕士学位论文]．哈尔滨，哈尔滨工业大学．2003
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59 王同海．管材塑性加工技术．机械工业出版社，1998：91-102，146-176
60 Carleer B, Kevie G,Winter L, etal. Analysis of the effect of matedal properties on the hydroforming process of tubes. Journal of Materials Processing Technology,2000,104:158-166
2 Y. S. Shin,H.M.Kim,B. H. Jeon, S. I. Oh. Prototype Tryout and Die Design for Automotive Parts Using Welded Blank Hydroforming. Journal of Materials Processing Technology, 2002, 130 (131):121-127
3 L.H. Lang,Z. R. Wang, D. C. Kang, S. J. Yuan,S. H. Zhang, J. Danckert,K. B. Nielsen. Hydroforming Highlights:Sheet Hydroforming and Tube Hydroforming. Journal of Materials Processing Technology,2004,151:165-177
4 R. Zhang, T. S. Zhang. Nodie Explosive Forming of Spherical Pressure Vesseis. J.M. Process Technol, 1994,41:341-347
5 张洪欣．汽车设计．第2版．北京：机械工业出版社，1998：146-148
6 朱伟成，徐成林，张玉成等．内高压成形汽车管件技术．汽车工艺与材料．2004，1：12-14
7 Terumori Ueda.Differential Gear Casting for Automobiles by Liquid. Bulge Forming Process PartⅡ. Sheet Metal Industries, 1983,60(4):48-56
8 Muammer Koc.Taylan A|tan.An Overall Review of the Tube Hydroforming Technology.Journal of Mate rials Processing Technology, 2001,108:384-393
9 S. H. Zhang. Developments in Hydroforming, Journal of materials Processing Technology, 1999, 91:236-244
10 Klaus Siegert. Markus HaEussermann.Recent Development in Hydroforming Technology. Journal of Materials Processing Technology, 2000,98:251-258
11 T.Sokolowski,K. Gerke,Evaluation of Tube Formability and Material Characteristics Hydraulic Bulge Testing of Tube. Journal of Materials Processing Technology, 2000, 98:34-40
12 Dohmann,Ch. Hartl. Hydroforming Method to Manufacture Light Weight Parts. Journal of Materials Processing Technology. 1996:669-676
13 F. Dohmann,Ch.. Hartl. Tube Hydroforming Research and Practical Application Journal of Materials Processing, Technology. 1997, 71:174-186
14 B. Carleer, G. vander Kevie,Lde Wintervan Veldhuizen. Analysis of the Effect of Material Properties on the Hydroforming Process of Tubes. Journal of Materials Processing Technology,2000,104:158-166
15 苑世剑．我国内高压成形技术现状与进展．锻压技术．2004，3：1-5
16 桂龙明，王桢．简议内高压成型技术．工艺与材料．2001，11：37-40
17 苑世剑，苗启斌，王仲仁．轿车后纵轴臂内高压成形研究．金属成形工艺．2004，22(3)：1-3
18 王连东．回转壳体正负成形理论及汽车桥壳胀形工艺的研究．[燕山大学工学博士论文]．2001：43-73
19 苑世剑，韩聪，刘刚，等．轿车副车架内高压成形．锻压技术．2004，3：41-44
20 苑世剑．内高压成形技术现状与发展趋势．金属成形工艺．2003，4(21)：32-34
21 郭成，杨连发．内补液增压式THF性能测试装置开发及实验研究．机械工程学报．2005，9：180-184
22 王连东，张涛，李礽．确定汽车桥壳液压胀形极限成形系数的初探．燕山大学学报，2001，25(3)：205-208
23 王连东，刘助柏，李礽．汽车桥壳复合液压胀形成形系数研究及力参量匹配．塑性工程学报，2001，8(3)：59-62
24 王连东．刘助柏．汽车桥壳液压胀形环向小圆角成形的研究．塑性工程学报，2001，8(4)：36-39
25 王连东，梁辰，李文平，等．液压胀形汽车桥壳成形理论及其试验研究．农业机械学报，2003，34(1)：124-203
26 白木，子荫．全数字化技术及其在汽车行业的应用．装备机械，2003(3)：26-27
27 任卫群，张云清，王书亭．数字化设计在汽车零部件开发中的应用．湖北汽车，2003(3)：20-24
28 求是科技．visual basic 6.0数据库开发技术与工程实践．人民邮电出版社，2004，1：1-64
29 吴绪略，曹强，曲秀丽．浅述数据库的现状与未来．山东电子2001，1：3-5
30 求是科技．visual C++什数据库开发技术与工程实践．人民邮电出版，2004，1：1-15
31 张应中，罗晓芳．基于技术的UG/Open API参数化标准件库的开发．计算机工程，2003，29(21)：180-181
32 张秀萍，孙文磊．基于UG的三维标准件库的建立方法．新疆大学学报(自然科学版)，2004，21(1)：84-56
33 于昂，张益华．UG界面开发技术在汽车模具设计中的应用．机械丁程与自动化，2005 (1):29-31
34 Geoffrey W. Rowe. Principles of Industrial Metalworking Process. Edward Arnold (Publishers)Ltd, 1977:156-159
35 张冶，洪雪，张泽帮．Unigraphics NX参数化设计实例教程．北京．清华大学出版社．2003，8：334-349
36 曾向阳．基于UG的装配用三维标准件图库的开发[C]．北京：机械工业出版社，1999
37 姚建国．制造业信息化工程的关键技术及应用[A]．北京：机械工业出版社，1999
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