基于UG的板管成形模拟前处理系统关键技术研究
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摘要
CAE技术已在板管成形模拟领域得到广泛的应用,是先进制造技术的重要组成部分。传统CAE软件由于操作繁琐,分析模型与设计模型通过中间数据格式转换时存在数据丢失,已无法适用于“CAE软件面向产品设计全流程”的发展需求。CAD/CAE的一体化集成能很好地避免数据丢失缺陷,降低CAE分析的难度,极大提高产品设计效率,已成为板管成形模拟领域的主流发展趋势。
论文结合国家自然科学基金资助项目“面向自主设计的汽车覆盖件成形性快速仿真及工艺优化技术研究”(N0.50575080)和国家科技支撑计划项目“基于SOA的数字化模具设计制造集成系统”(No.2006BAF01A43),深入研究和探讨了基于UG平台的板管成形模拟前处理系统的若干关键技术问题。
通过对板管成形基本工艺、CAD/CAE集成系统开发难点、有限元数值模拟软件研究现状、CAD/CAE集成现状进行研究和探讨,明确了未来板管成形有限元模拟前处理系统开发的发展方向,并从UG开发平台的技术特点和系统有限元模拟求解器两个方面介绍了系统的开发基础。
以基于UG平台的面向板管成形产品设计全流程的FASTAMP-NX前处理系统为研究对象,从分析模型几何特征定义、有限元网格剖分、成形工具自动装配、系统数据处理、工艺参数处理、成形过程动画显示等方面对系统若干关键技术进行了研究和探讨;通过分析对比主流CAD平台如CATIA、Pro/E、SolidWorks与UG平台的技术共性,论证了FASTAMP-NX前处理系统采用的若干关键技术同样适用于基于上述平台的同类系统的开发。
论文最后介绍了FASTAMP-NX前处理系统的总体架构与工作流程,并通过工业应用实例验证了其面向板管成形产品设计全流程的实用性和可行性。
CAE technology has been widely applied in sheet & tube forming simulation field, which is the key component of advanced manufacturing technology. The traditional CAE software isn’t suitable for the demand of“CAE software should be available to the total process of product design”due to the defect of complicated operation and the data lost between analysis model and design model when they convert through intermediate data format. CAD/CAE seamless integration can wonderfully avoid the data lost defect, reduce the CAD analysis difficulty and enormously improve the design efficiency, so it’s becoming the main development trend in sheet & tube forming simulation field.
The research of this paper is supported by the NSF project“The Independent Research of High-speed Simulation and Optimal Process Design aiming to the Formability of Automobile Panel”(NO.50575080) and the National Key Technology R&D Program“Numerical Die Design and Manufacture System Based on SOA”(No. 2006BAF01A43), which has delved into the key technologies of sheet & tube forming simulation pre-process system based on UG platform.
The paper has defined the development direction of the sheet & tube forming simulation pro-process system by means of researching and discussing the sheet & tube forming basic technology, the difficulty of CAD/CAE integrated system’s development, the current research statuses of FE numerical simulation software and CAD/CAE seamless integration. At the same time, it has introduced the development foundation of the system as viewed from UG platform’s technical characteristics and FE solver.
The research of this paper is based on the pre-process system of FASTAMP-NX, which is oriented to the sheet & tube forming product design’s total process based on UG platform. The paper also introduces some key technologies of the system from analysis model geometry feature defining, FEM mesh generating, forming tools automatically assembling, system data processing, technical parameters processing and forming process animation displaying. By means of anglicizing and contrasting the common technologies between the mainstream CAD platform such as CATIA, Pro/E and SolidWorks and UG platform, the paper advances the view that the key technologies of the pre-process system of FASTAMP-NX are also suitable for the similar system’s development which is based on above-mentioned platform.
At last, the paper introduces the total frame and workflow of the pre-process system of FASTAMP-NX, verifies the practicability and feasibility of system’s sheet & tube forming product design’s total process oriented function by means of industrial application projects.
论文结合国家自然科学基金资助项目“面向自主设计的汽车覆盖件成形性快速仿真及工艺优化技术研究”(N0.50575080)和国家科技支撑计划项目“基于SOA的数字化模具设计制造集成系统”(No.2006BAF01A43),深入研究和探讨了基于UG平台的板管成形模拟前处理系统的若干关键技术问题。
通过对板管成形基本工艺、CAD/CAE集成系统开发难点、有限元数值模拟软件研究现状、CAD/CAE集成现状进行研究和探讨,明确了未来板管成形有限元模拟前处理系统开发的发展方向,并从UG开发平台的技术特点和系统有限元模拟求解器两个方面介绍了系统的开发基础。
以基于UG平台的面向板管成形产品设计全流程的FASTAMP-NX前处理系统为研究对象,从分析模型几何特征定义、有限元网格剖分、成形工具自动装配、系统数据处理、工艺参数处理、成形过程动画显示等方面对系统若干关键技术进行了研究和探讨;通过分析对比主流CAD平台如CATIA、Pro/E、SolidWorks与UG平台的技术共性,论证了FASTAMP-NX前处理系统采用的若干关键技术同样适用于基于上述平台的同类系统的开发。
论文最后介绍了FASTAMP-NX前处理系统的总体架构与工作流程,并通过工业应用实例验证了其面向板管成形产品设计全流程的实用性和可行性。
CAE technology has been widely applied in sheet & tube forming simulation field, which is the key component of advanced manufacturing technology. The traditional CAE software isn’t suitable for the demand of“CAE software should be available to the total process of product design”due to the defect of complicated operation and the data lost between analysis model and design model when they convert through intermediate data format. CAD/CAE seamless integration can wonderfully avoid the data lost defect, reduce the CAD analysis difficulty and enormously improve the design efficiency, so it’s becoming the main development trend in sheet & tube forming simulation field.
The research of this paper is supported by the NSF project“The Independent Research of High-speed Simulation and Optimal Process Design aiming to the Formability of Automobile Panel”(NO.50575080) and the National Key Technology R&D Program“Numerical Die Design and Manufacture System Based on SOA”(No. 2006BAF01A43), which has delved into the key technologies of sheet & tube forming simulation pre-process system based on UG platform.
The paper has defined the development direction of the sheet & tube forming simulation pro-process system by means of researching and discussing the sheet & tube forming basic technology, the difficulty of CAD/CAE integrated system’s development, the current research statuses of FE numerical simulation software and CAD/CAE seamless integration. At the same time, it has introduced the development foundation of the system as viewed from UG platform’s technical characteristics and FE solver.
The research of this paper is based on the pre-process system of FASTAMP-NX, which is oriented to the sheet & tube forming product design’s total process based on UG platform. The paper also introduces some key technologies of the system from analysis model geometry feature defining, FEM mesh generating, forming tools automatically assembling, system data processing, technical parameters processing and forming process animation displaying. By means of anglicizing and contrasting the common technologies between the mainstream CAD platform such as CATIA, Pro/E and SolidWorks and UG platform, the paper advances the view that the key technologies of the pre-process system of FASTAMP-NX are also suitable for the similar system’s development which is based on above-mentioned platform.
At last, the paper introduces the total frame and workflow of the pre-process system of FASTAMP-NX, verifies the practicability and feasibility of system’s sheet & tube forming product design’s total process oriented function by means of industrial application projects.
引文
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[2]杨玉英.大型薄板成形技术[M]. (第一版).北京:国防工业出版社, 1996
[3]柳玉起.计算机模拟在金属成形行业的应用和发展现状[J].锻造与冲压, 2005, (6) :16-22
[4] M.J. Worswick, Numerical Simulation of Sheet Metal Forming[J]. Metal Forming Science and Practice, 2002: 135-181
[5] M. Firat. Computer aided analysis and design of sheet metal forming processes: Part I– The finite element modeling concepts[J]. Materials & Design, 2007, 28(4): 1298-1303
[6] Yang Jusheng, Yang Nan. A brief review of FEM software technique. Advances in Engineering Software[J], 1993, 17(3): 195-200
[7]汪晨,张质良.金属板料CAE系统及其应用[J].中国机械工程, 1997, (4): 43-45.
[8]董湘怀.材料成形计算机模拟[M]. (第一版).北京:机械工业出版社, 2002
[9] Kao Yungchou, Cheng Shinyu, She Chenhua. Development of an integrated CAD/CAE/CAM system on taper-tipped thread-rolling die-plates[J]. Journal of Materials Processing Technology, 2006, 177(1-3): 98-103
[10]沈其文.材料成形工艺基础[M]. (第三版).武汉:华中科技大学出版社, 2003
[11]夏巨谌.塑性成形工艺及设备[M]. (第一版).北京:机械工业出版社, 2001
[12]朱伟成,徐成林,宋宝阳等[J].冲压技术发展趋势.汽车工艺与材料, 2007, (1): 16-20
[13]夏巨谌,张启勋.材料成形工艺[M]. (第一版).北京:机械工业出版社, 2004
[14]苑世剑,李洪洋,戴昆.轻量化结构内高压成形技术[J].材料科学与工艺, 1999, 7(1): 43-48
[15]苑世剑.内高压成形技术现状与发展趋势[J].金属成形工艺, 2003, 3(2): 1-3
[16]杜亭.板料成形有限元模拟前后置处理系统的设计与实现: [硕士学位论文].武汉:华中科技大学, 2004
[17] Gordon S. An analyst’s view: STEP-enabled CAD-CAE integration[C]. In: Presentation materials of NASA’s STEP for aerospace workshop. Jet Propulsion Laboratory, Pasadena, CA: 2001, 01
[18] Sang Hun Lee. A CAD–CAE integration approach using feature-based multi-resolution andmulti-abstraction modelling techniques[J]. Computer-Aided Design , 2005, 37: 941–955
[19] M. Tisza. Numerical modelling and simulation in sheet metal forming[J]. Journal of Materials Processing Technology, 2004, 151(1-3): 58-62
[20] Arthur Tang, Wing Lee. Die Face Engineering based Springback Compensation and Implementation[C]. In: Proceedings of the 6th International Conference and Workshop on Numerical Simualtion of 3D Sheet Metal Forming Processes. Detroit, MI: 2005, 8: 50-59
[21] Du Ting, Liu Yuqi, Zhang Zhibing, et al. Fast FE analysis system for sheet metal stamping-FASTAMP[J]. Journal of Materials Processing Technology, 2007, 187-188: 402-406
[22]丁祎,胡平,曹颖等. KMAS冲压分析CAE软件在车身件设计及工艺预分析中的应用[J].吉林大学学报:工学版, 2005, 35( 2): 148-152,162
[23]施法中,张苏,刘艳芳等.冲压成形模拟软件SheetForm的实用化开发及体会[C].见:第十五届全国汽车车身技术研讨会论文集.中国成都:中国汽车工程学位汽车车身技术分会, 2005,10. 422-429
[24] N. Alberti, L. Fratini. Innovative sheet metal forming processes: numerical simulations and experimental tests[J]. Journal of Materials Processing Technology, 2004, 150(1-2): 2-9
[25] Shinichiro Fujikawa. Application of CAE for hot-forging of automotive components[J]. Journal of Materials Processing Technology, 2000, 98(2): 176-181
[26]刘祖良,庞守关,郑继周. CAD/CAE代表软件集成接口技术浅析[J].机械研究与应用, 2007, 20(4): 104-106
[27]龚科家,胡平.汽车覆盖件模面设计中补充曲面的生成方法[J].吉林大学学报(工学版), 2006, 36(1): 63-66
[28]王伟,施法中.覆盖件拉延模型工艺补充部分的参数化设计[J].锻压技术, 2007, 32(2): 105-109
[29] L. Wang. Integration of CAD and boundary element analysis through subdivision methods[J]. Computers & Industrial Engineering, 2009,1: 1-4
[30] Suresh K. Automating the CAD/CAE dimensional reduction process[C]. In: Proceedings of the eighth ACM symposium on solid modeling and applications. Seattle, WA, USA: 2003. 76-85.
[31] AutoForm Engineering GmbH, www.autoform.com/products/product_onestep_catia.html
[32] ETA Inc. www.eta.com/index.php?option=com_content&task=view&id=35&Itemid=70
[33] ESI GROUP, www.esi-group.com.cn/news/VM_CATIA_V5_PAM-TFA.htm
[34] Forming Technologies Inc, http://www.forming.com/catblankv5.htm
[35] Forming Technologies Inc, http://www.forming.com/dynavista.htm
[36] Dong-Chan Lee, Chang-Soo Han. CAE (computer aided engineering) driven durability model verification for the automotive structure development[J]. Finite Elements in Analysis and Design, 2009, 45(5): 324-332
[37]杜亭,柳玉起,章志兵等.基于UGSNX的板料成形快速仿真系统[J],锻压技术, 2008, 33(4): 145~149
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