基于CATIA的板料成形全工序仿真前处理系统的设计和开发
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摘要
板料成形有限元数值模拟技术的应用,提高了汽车覆盖件的生产效率,推动了汽车工业的快速发展。但是传统的板料成形CAE软件一般都只针对单工序成形,CAD设计完成后,进行CAE分析需要数据转换,往往导致模型数据的丢失,增加数值模拟前处理的时间,影响成形模拟的精度。因此,为了满足汽车覆盖件流水线和多工序的生产需求,提高产品的生产效率,减少产品的生产成本,开发基于CAD平台的板料成形CAE系统,实现CAD和CAE技术的无缝集成,对汽车覆盖件的生产乃至整个汽车工业领域都有十分重要的意义。
本课题来源于国家自然基金项目“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”(编号为50575080)和国家“863”计划“基于仿真的汽车零部件可成形性设计与工艺优化”(编号为2006AA04Z140)。课题采用CAA二次开发技术,设计和开发出基于CATIA V5平台的汽车覆盖件全工序成形仿真前置处理系统。
论文阐述了CAD/CAE技术的集成现状和发展趋势,结合CATIA二次开发工具和开发环境,讨论了系统的开发框架和设计思想。通过分析传统的专用板料CAE有限元软件和全工序模拟的功能需求特点,确立了系统的总体架构和工作流程。在紧密结合生产实际和充分发挥CAD平台的优势的前提下,实现模块化操作和节点式管理的设计特点。在此基础上,解决了虚拟装配技术、参数化关联设计技术、工具网格离散技术和属性存储技术等关键问题,实现汽车覆盖件全工序成形仿真前置处理系统的所有功能。
基于CATIA平台开发的板料成形全工序仿真系统,实现了CAD和CAE的无缝集成。该系统可以设置真实的摩擦、压边力、拉深筋、切口线等实际工艺条件参数,对拉延、修边、翻边等成形工序进行快速准确的模拟,并可初步实现回弹预测功能。通过对典型的汽车覆盖件多工序成形展开模拟,充分体现了系统参数化、流程化和简单化的特点,验证了系统的准确性和稳定性。
The application of FEM technology in numerical simulation of metal sheet forming raises the productivity of automobile panel and promotes development of auto industry. But the current software of sheet forming analysis is always applied to simulate the single process, and needs data transition between CAD and CAE platform which trends to cause the loss of model data, increase the time of the pre-processor operation and lower the result precision of simulation. So, in order to meet the needs of flow line and multi-process production, raise the productivity and reduce costs, the development of sheet forming CAE system integrated seamlessly with CAD platform is necessary and significant to automobile production and the whole auto industry.
This research is one part of NSF program named: "The Independent Research of High-speed Simulation and Optimal Process Design aiming at the Formability of Automobile Panel" (NO.50575080) and National 863 program named: "The Formability and Optimal Process Design Based on the Simulation of Automobile Parts"(NO. 2006AA04Z140). With the CAA secondary development technology, the project completed the design and the development of complete stamping process CAE pre-processor system based on CATIA V5.
In this paper, the author describes the trend of CAD/CAE integration, introduces the environment and tools of CAA secondary development, and discusses the frame and design philosophy of the system. Through analysis of the special software of simulation of sheet forming, the overall structure and workflow are determined. According to the factual production, the system takes full advantage of CAD with characteristics of modular operation and node-type management. Meanwhile, the key technology such as the virtual assembly, parameterized associated design, tool mesh tessellation, attribute storage and so on has been solved. Finally, all functions of the system have been implemented.
The simulation of sheet forming system based on CATIA V5 carries out the seamless integration between CAD and CAE. The system considers the influence of friction, holding force, draw-bead and other actual process conditions, can simulate drawing, trimming, flanging process, and evaluate the spring-back trend. Simulation to typical automobile panels has reflected the parameterized, simplified and modular characteristics of the system and proved its accuracy and stability.
本课题来源于国家自然基金项目“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”(编号为50575080)和国家“863”计划“基于仿真的汽车零部件可成形性设计与工艺优化”(编号为2006AA04Z140)。课题采用CAA二次开发技术,设计和开发出基于CATIA V5平台的汽车覆盖件全工序成形仿真前置处理系统。
论文阐述了CAD/CAE技术的集成现状和发展趋势,结合CATIA二次开发工具和开发环境,讨论了系统的开发框架和设计思想。通过分析传统的专用板料CAE有限元软件和全工序模拟的功能需求特点,确立了系统的总体架构和工作流程。在紧密结合生产实际和充分发挥CAD平台的优势的前提下,实现模块化操作和节点式管理的设计特点。在此基础上,解决了虚拟装配技术、参数化关联设计技术、工具网格离散技术和属性存储技术等关键问题,实现汽车覆盖件全工序成形仿真前置处理系统的所有功能。
基于CATIA平台开发的板料成形全工序仿真系统,实现了CAD和CAE的无缝集成。该系统可以设置真实的摩擦、压边力、拉深筋、切口线等实际工艺条件参数,对拉延、修边、翻边等成形工序进行快速准确的模拟,并可初步实现回弹预测功能。通过对典型的汽车覆盖件多工序成形展开模拟,充分体现了系统参数化、流程化和简单化的特点,验证了系统的准确性和稳定性。
The application of FEM technology in numerical simulation of metal sheet forming raises the productivity of automobile panel and promotes development of auto industry. But the current software of sheet forming analysis is always applied to simulate the single process, and needs data transition between CAD and CAE platform which trends to cause the loss of model data, increase the time of the pre-processor operation and lower the result precision of simulation. So, in order to meet the needs of flow line and multi-process production, raise the productivity and reduce costs, the development of sheet forming CAE system integrated seamlessly with CAD platform is necessary and significant to automobile production and the whole auto industry.
This research is one part of NSF program named: "The Independent Research of High-speed Simulation and Optimal Process Design aiming at the Formability of Automobile Panel" (NO.50575080) and National 863 program named: "The Formability and Optimal Process Design Based on the Simulation of Automobile Parts"(NO. 2006AA04Z140). With the CAA secondary development technology, the project completed the design and the development of complete stamping process CAE pre-processor system based on CATIA V5.
In this paper, the author describes the trend of CAD/CAE integration, introduces the environment and tools of CAA secondary development, and discusses the frame and design philosophy of the system. Through analysis of the special software of simulation of sheet forming, the overall structure and workflow are determined. According to the factual production, the system takes full advantage of CAD with characteristics of modular operation and node-type management. Meanwhile, the key technology such as the virtual assembly, parameterized associated design, tool mesh tessellation, attribute storage and so on has been solved. Finally, all functions of the system have been implemented.
The simulation of sheet forming system based on CATIA V5 carries out the seamless integration between CAD and CAE. The system considers the influence of friction, holding force, draw-bead and other actual process conditions, can simulate drawing, trimming, flanging process, and evaluate the spring-back trend. Simulation to typical automobile panels has reflected the parameterized, simplified and modular characteristics of the system and proved its accuracy and stability.
引文
[1]余雷,袁国定,岳陆游.有限元数值模拟在汽车覆盖件设计和制造中的应用[J].锻压技术,2002, 27(2):23-26
[2]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[J].机电工程技术, 2004,33(5):23-26.
[3]郑莹,吴勇国,李尚健,李志刚,肖景容.板料成形数值模拟进展.塑性工程学报[J], 1996, 3(4):34-47.
[4] P.V. Macal, I.D. King. Elastic-plastic analysis of two-dimension stress systems by finite element method. J.Mech.Sci, 1967,9(10):143-150.
[5] Kobayashis, J H Kim. Deformation analysis of axisymmetric sheet metal forming processed by rigid-plastic finite element method. Mechanics of Sheet Metal Forming, 1978: 341-365.
[6] Wang N M, Wenner M L. Elastic-viscoplastic analysis of simple stretching forming process. Mechanics of Sheet Metal Forming, 1978: 367-391.
[7] Honecker A, Mattiason K. Finite Element Procedures for metal sheet forming simulation[c]. Thompson E G. NUMIFORM’89. Netherlands.1989:457-464.
[8] N. Boudeau, J.C. Gelin. Finite element simulation of the ductile fracture in 3-D sheet metal forming process. Journal of Materials Processing Technology, 1992, 32(1-2): 521-530.
[9]张卫刚,胡轶敏,陈关龙等.桑塔纳轿车车顶冲压成形动态仿真研究.汽车工程, 1998, 20(3): 187-192.
[10]钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用[M].北京:北京理工大学出版社,1998.
[11]林忠钦,胡轶敏,陈关龙等.轿车侧框冲压成形过程的仿真与试验分析.上海交通大学学报, 1998, 11: 60~65.
[12]雷亚勇,张韫韬,刘鑫.CAD/CAE/CAM的协同发展研究.机械工程与自动化,2008,4:191-193.
[13]张晓静,周贤兵.板料成形回弹模拟塑性工程学报.1999,6(3):56-62.
[14]董湘怀.轴对称及三维金属板料成形过程的有限元模拟: [博士学位论文].武汉:华中科技大学, 1991.
[15]胡平.弹塑性有限变形的拟流动理论.力学学报, 1994, 26(3): 275~283.
[16]柳玉起.板材成形塑性流动规律及起皱回弹的数值研究: [博士学位论文].长春:吉林工业大学, 1996.
[17]柳玉起,杜亭,章志兵.板料成形快速分析软件FASTAMP.材料科学与工艺, 2004(04):353-356.
[18]杜亭,柳玉起,章志兵等.面向设计的板料成形快速仿真系统FASTAMP.中国机械工程(增刊), 2006,17:83-85,114.
[19] AutoForm Engineering Company. AutoForm-DieDesigner User’s Manual, 2001.
[20] Engineering Technology Associates, Inc. DYNAFORM v5.6 user guide, 2007.
[21]那景新,柳玉起,曹颖等.油底壳一次拉延的计算机仿真与实验验证.中国机械工程,2000,11(6):675-678.
[22]李贵.汽车覆盖件全工序成形模拟前置处理系统的设计与开发:[硕士学位论文].武汉:华中科技大学,2008.
[23] H.S. Lee, S.L. Chang. Development of a CAD/CAE/CAM system for a robot manipulator. Journal of Materials Processing Technology. 2003, 140(1-3), 22 September Pages 100-104.
[24] Yung-Chou Kao, Hsin-Yu Cheng, Chen-Hua She. Development of an integrated CAD/CAE/CAM system on taper-tipped thread-rolling die-plates. Journal of Materials Processing Technology. 2006, 177(1-3):98-103.
[25] Altair Engineering Company. HyperWorks User’s Manual. 2004.
[26]章志兵,王同俊,柳玉起等.汽车覆盖件修边与翻边工序的快速仿真系统.见:第十届全国塑性工程学术年会,第三届国际塑性加工先进技术研讨会论文集.南昌:全国塑性工程学会, 2007,10:844-848.
[27]王同俊.基于UG的板料成形全工序仿真前处理系统的设计与开发:[硕士学位论文].武汉:华中科技大学,2008.
[28]胡平.覆盖件模具CAD/CAE/CAM一体化技术现状与发展.机械工人, 2000(10):3-4.
[29]张世莹.欧洲CATIA-CADAM会议[J].世界制造技术与装备市场, 2001,1:56-57.
[30]谢哲川.基于CATIA V5的知识工程的轿车车身设计.CAD/CAM与制造业信息化.2007,1:44-46.
[31]谢岳峰,余雄庆.基于CATIA二次开发的飞机外形参数化设计.计算机工程与设计.2008, 14(29):3792-3794.
[32] Dassault Systemes. CAA V5 R14 documentation. July, 2004.
[33]张敏,苏兰海,王君英.基于CAA的CATIA用户自定义特征创建.机械设计与制造[J].2008,9:87-88.
[34] Dale Rogerson. Inside Com. Microsoft Press. Washington, USA, 1997.
[35]潘爱民.COM原理与应用[M].北京:清华大学出版社,2000.
[36]王昱皓,施法中,陈中奎.金属板料成形CAE系统的前后置处理中几个关键技术的处理.锻压技术, 2004, (3): 33~34
[37] Frederick C O. along Y C, Edge F W. Two Dimensional Automatic Mesh Generation for Structural Analysis. International Journal for Numerical Methods in Engineering, 1970, (2): 113-144.
[38] Ho. Le K. Finite Element Mesh Generation Methods: a Review and Classification. Computer Aided Design, 1988, (20): 27-38.
[39]谢邵辉,柳玉起,杜亭.冲压成形模拟过程中的工艺切口算法及应用.中国机械工程.2007: 1-4.
[40]沈启彧,虞春,卫原平,阮雪榆.金属板料成形工艺CAD/CAE智能化集成研究.锻压技术.2000,1:17-20.
[41]齐从谦,崔琼瑶.基于参数化技术的设计方法研究.机械设计与研究, 2002, 18(5):13~15.
[42]杨骥.飞机构件虚拟装配技术研究:[硕士学位论文].南京:南京航空航天大学,2007.
[43]张胜兰,石正鹏,胡群.CATIA V5在引擎盖逆向造型中的应用.制造业自动化,2008,2(30):65-67.
[44]马骥飞.轿车行李箱盖内板成形数值模拟及工艺参数优化:[硕士学位论文].长春:吉林大学,2007.
[45]赵东旭.轻量化车用钢板冲压成形与回弹数值仿真及工艺优化:[博士学位论文].长春:吉林大学,2007.
[2]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[J].机电工程技术, 2004,33(5):23-26.
[3]郑莹,吴勇国,李尚健,李志刚,肖景容.板料成形数值模拟进展.塑性工程学报[J], 1996, 3(4):34-47.
[4] P.V. Macal, I.D. King. Elastic-plastic analysis of two-dimension stress systems by finite element method. J.Mech.Sci, 1967,9(10):143-150.
[5] Kobayashis, J H Kim. Deformation analysis of axisymmetric sheet metal forming processed by rigid-plastic finite element method. Mechanics of Sheet Metal Forming, 1978: 341-365.
[6] Wang N M, Wenner M L. Elastic-viscoplastic analysis of simple stretching forming process. Mechanics of Sheet Metal Forming, 1978: 367-391.
[7] Honecker A, Mattiason K. Finite Element Procedures for metal sheet forming simulation[c]. Thompson E G. NUMIFORM’89. Netherlands.1989:457-464.
[8] N. Boudeau, J.C. Gelin. Finite element simulation of the ductile fracture in 3-D sheet metal forming process. Journal of Materials Processing Technology, 1992, 32(1-2): 521-530.
[9]张卫刚,胡轶敏,陈关龙等.桑塔纳轿车车顶冲压成形动态仿真研究.汽车工程, 1998, 20(3): 187-192.
[10]钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用[M].北京:北京理工大学出版社,1998.
[11]林忠钦,胡轶敏,陈关龙等.轿车侧框冲压成形过程的仿真与试验分析.上海交通大学学报, 1998, 11: 60~65.
[12]雷亚勇,张韫韬,刘鑫.CAD/CAE/CAM的协同发展研究.机械工程与自动化,2008,4:191-193.
[13]张晓静,周贤兵.板料成形回弹模拟塑性工程学报.1999,6(3):56-62.
[14]董湘怀.轴对称及三维金属板料成形过程的有限元模拟: [博士学位论文].武汉:华中科技大学, 1991.
[15]胡平.弹塑性有限变形的拟流动理论.力学学报, 1994, 26(3): 275~283.
[16]柳玉起.板材成形塑性流动规律及起皱回弹的数值研究: [博士学位论文].长春:吉林工业大学, 1996.
[17]柳玉起,杜亭,章志兵.板料成形快速分析软件FASTAMP.材料科学与工艺, 2004(04):353-356.
[18]杜亭,柳玉起,章志兵等.面向设计的板料成形快速仿真系统FASTAMP.中国机械工程(增刊), 2006,17:83-85,114.
[19] AutoForm Engineering Company. AutoForm-DieDesigner User’s Manual, 2001.
[20] Engineering Technology Associates, Inc. DYNAFORM v5.6 user guide, 2007.
[21]那景新,柳玉起,曹颖等.油底壳一次拉延的计算机仿真与实验验证.中国机械工程,2000,11(6):675-678.
[22]李贵.汽车覆盖件全工序成形模拟前置处理系统的设计与开发:[硕士学位论文].武汉:华中科技大学,2008.
[23] H.S. Lee, S.L. Chang. Development of a CAD/CAE/CAM system for a robot manipulator. Journal of Materials Processing Technology. 2003, 140(1-3), 22 September Pages 100-104.
[24] Yung-Chou Kao, Hsin-Yu Cheng, Chen-Hua She. Development of an integrated CAD/CAE/CAM system on taper-tipped thread-rolling die-plates. Journal of Materials Processing Technology. 2006, 177(1-3):98-103.
[25] Altair Engineering Company. HyperWorks User’s Manual. 2004.
[26]章志兵,王同俊,柳玉起等.汽车覆盖件修边与翻边工序的快速仿真系统.见:第十届全国塑性工程学术年会,第三届国际塑性加工先进技术研讨会论文集.南昌:全国塑性工程学会, 2007,10:844-848.
[27]王同俊.基于UG的板料成形全工序仿真前处理系统的设计与开发:[硕士学位论文].武汉:华中科技大学,2008.
[28]胡平.覆盖件模具CAD/CAE/CAM一体化技术现状与发展.机械工人, 2000(10):3-4.
[29]张世莹.欧洲CATIA-CADAM会议[J].世界制造技术与装备市场, 2001,1:56-57.
[30]谢哲川.基于CATIA V5的知识工程的轿车车身设计.CAD/CAM与制造业信息化.2007,1:44-46.
[31]谢岳峰,余雄庆.基于CATIA二次开发的飞机外形参数化设计.计算机工程与设计.2008, 14(29):3792-3794.
[32] Dassault Systemes. CAA V5 R14 documentation. July, 2004.
[33]张敏,苏兰海,王君英.基于CAA的CATIA用户自定义特征创建.机械设计与制造[J].2008,9:87-88.
[34] Dale Rogerson. Inside Com. Microsoft Press. Washington, USA, 1997.
[35]潘爱民.COM原理与应用[M].北京:清华大学出版社,2000.
[36]王昱皓,施法中,陈中奎.金属板料成形CAE系统的前后置处理中几个关键技术的处理.锻压技术, 2004, (3): 33~34
[37] Frederick C O. along Y C, Edge F W. Two Dimensional Automatic Mesh Generation for Structural Analysis. International Journal for Numerical Methods in Engineering, 1970, (2): 113-144.
[38] Ho. Le K. Finite Element Mesh Generation Methods: a Review and Classification. Computer Aided Design, 1988, (20): 27-38.
[39]谢邵辉,柳玉起,杜亭.冲压成形模拟过程中的工艺切口算法及应用.中国机械工程.2007: 1-4.
[40]沈启彧,虞春,卫原平,阮雪榆.金属板料成形工艺CAD/CAE智能化集成研究.锻压技术.2000,1:17-20.
[41]齐从谦,崔琼瑶.基于参数化技术的设计方法研究.机械设计与研究, 2002, 18(5):13~15.
[42]杨骥.飞机构件虚拟装配技术研究:[硕士学位论文].南京:南京航空航天大学,2007.
[43]张胜兰,石正鹏,胡群.CATIA V5在引擎盖逆向造型中的应用.制造业自动化,2008,2(30):65-67.
[44]马骥飞.轿车行李箱盖内板成形数值模拟及工艺参数优化:[硕士学位论文].长春:吉林大学,2007.
[45]赵东旭.轻量化车用钢板冲压成形与回弹数值仿真及工艺优化:[博士学位论文].长春:吉林大学,2007.