车门防撞梁热冲压试验研究与材料性能梯度优化
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摘要
随着我国汽车保有量的增加以及道路交通的迅猛发展,汽车在各种交通状况下发生的碰撞事故也呈上升趋势。其中侧面碰撞是发生频率最高和造成人员伤亡最多的交通事故形态之一。汽车侧面是车门,强度较为薄弱。在碰撞过程中,车门内板的侵入速度和侵入距离是造成乘员伤害的主要原因,如何减小车门内板的侵入速度和侵入距离是提高汽车侧面碰撞安全性的重要途径。车门防撞梁作为车门的加强件来抵御侧面碰撞,它能够大大减轻侧门的变形程度,从而能减少汽车撞击对车内乘员的伤害。因此对车门内部的车门防撞梁进行优化设计,提高车门刚度,进而提高汽车侧面碰撞安全性,对提高乘员的安全防护和改善道路交通安全有着非常重要的意义。
为了提高车门防撞梁的抗撞能力,改善其吸能性能,进而提升汽车侧面安全,本文提出利用超高强钢定制热成形技术制造强度不均一分布的单一厚度车门防撞梁。为了使定制热成形车门防撞梁的材料梯度分布趋于合理,利用LS-OPT及LS-DYNA对其进行了基于仿真的优化设计。基于响应面数值优化方法,采用部件碰撞仿真分析,对定制热成形车门防撞梁的材料性能梯度分布进行优化设计。
首先,本文在热冲压成形工艺分析的基础上,以热冲压后强度级别分别为1.5GPa、1.7GPa、1.9GPa、2.2GPa的热成形马氏体钢板为原料,设计制造热冲压模具,进行了小批量热冲压零件制备。通过调节各工艺参数优化热冲压工艺,成功试制出满足性能要求的热冲压车门防撞梁。采用金相显微镜、显微硬度仪和万能拉伸试验机等分析测试手段对成形件的组织和力学性能进行了分析。然后,本文参照GB15743和美国FMVSS214等车门强度检测试验标准对制得的热成形防撞梁进行了静压强度检测。基于上述实验,利用Hypermesh和LS-DYNA进行有限元建模和边界条件设置,对静压强度检测过程进行有限元模拟分析,通过将仿真分析结果与实验结果进行对比分析,验证了有限元模型的正确性和可靠性。最后,将防撞粱仿真分析结果作为优化设计的基础,采用部件碰撞仿真分析,以此进行单一厚度车门防撞粱材料性能梯度优化设计。根据零件的碰撞安全要求确定优化设计模型的目标、设计变量和约束条件等;采用拉丁超立方抽样在变量设计空间里选取样本点试验;根据结果基于响应面法建立车门防撞梁的二次多项式响应面模型;通过遗传优化算法得到了车门防撞梁材料性能的最优化分布。结果表明,优化后的变强度车门防撞梁在保证抗撞性能的前提下,改善了车门防撞梁的吸能效果,能在事故发生时对乘员提供更有效的保护。
本文对汽车车门防撞梁进行材料性能梯度优化设计,在一定范围内得到一种材料最优分布的防撞梁,提高了汽车车门乃至整车侧面的耐碰撞性能。本文的研究方法具有通用性,可广泛应用于各种车型的车门防撞梁。
With the increasing number of automobile, the trend of impact accidents caused by automobile in all kinds of traffic status is raising. Side-impact collisions are the second leading cause of death and injury in the traffic accidents after frontal crashes. Side impact beam are developed to reduce the velocity and depth of door intrusion into the passenger compartment in side impact crashes. Assessing the effectiveness of side impact beam is significant for reducing occupant fatalities and serious injuries.
In order to impove its side crashworthiness, a method using the hot formed side impact beam was proposed. The method produces the side impact beam with uniform thickness and varying yield strength by different cooling rate at hot forming. To make the distribution of the yield strength in the hot formed side impact beam reasonable, an optimization design was performed by the finite element analysis.
Ultra high strength steel was successfully produced by using hot stamping process. The microstructure of the samples was analyzed by microscope, and the tension strength and the hardness distribution of the samples were tested. The static character of side impact beam is analyzed by LS-DYNA through the interface of Hypermesh and LS-Prepost. The finite element model was built up according to FMVSS-214 and validated by the test data.
Based on the above results, an optimal distribution of the yield strength in the side impact beam material was obtained using the numerical optimization method of response surface and component collision simulation analysis. Before and after improvement simulation results show that the displacement, crashworthiness force and the effect of energy absorption are increase. The obtained results indicate that the crashworthiness of the front door and the whole car’s side can be improved by optimizing the side impact beam and finding the best distribution of material strength in certain range.
为了提高车门防撞梁的抗撞能力,改善其吸能性能,进而提升汽车侧面安全,本文提出利用超高强钢定制热成形技术制造强度不均一分布的单一厚度车门防撞梁。为了使定制热成形车门防撞梁的材料梯度分布趋于合理,利用LS-OPT及LS-DYNA对其进行了基于仿真的优化设计。基于响应面数值优化方法,采用部件碰撞仿真分析,对定制热成形车门防撞梁的材料性能梯度分布进行优化设计。
首先,本文在热冲压成形工艺分析的基础上,以热冲压后强度级别分别为1.5GPa、1.7GPa、1.9GPa、2.2GPa的热成形马氏体钢板为原料,设计制造热冲压模具,进行了小批量热冲压零件制备。通过调节各工艺参数优化热冲压工艺,成功试制出满足性能要求的热冲压车门防撞梁。采用金相显微镜、显微硬度仪和万能拉伸试验机等分析测试手段对成形件的组织和力学性能进行了分析。然后,本文参照GB15743和美国FMVSS214等车门强度检测试验标准对制得的热成形防撞梁进行了静压强度检测。基于上述实验,利用Hypermesh和LS-DYNA进行有限元建模和边界条件设置,对静压强度检测过程进行有限元模拟分析,通过将仿真分析结果与实验结果进行对比分析,验证了有限元模型的正确性和可靠性。最后,将防撞粱仿真分析结果作为优化设计的基础,采用部件碰撞仿真分析,以此进行单一厚度车门防撞粱材料性能梯度优化设计。根据零件的碰撞安全要求确定优化设计模型的目标、设计变量和约束条件等;采用拉丁超立方抽样在变量设计空间里选取样本点试验;根据结果基于响应面法建立车门防撞梁的二次多项式响应面模型;通过遗传优化算法得到了车门防撞梁材料性能的最优化分布。结果表明,优化后的变强度车门防撞梁在保证抗撞性能的前提下,改善了车门防撞梁的吸能效果,能在事故发生时对乘员提供更有效的保护。
本文对汽车车门防撞梁进行材料性能梯度优化设计,在一定范围内得到一种材料最优分布的防撞梁,提高了汽车车门乃至整车侧面的耐碰撞性能。本文的研究方法具有通用性,可广泛应用于各种车型的车门防撞梁。
With the increasing number of automobile, the trend of impact accidents caused by automobile in all kinds of traffic status is raising. Side-impact collisions are the second leading cause of death and injury in the traffic accidents after frontal crashes. Side impact beam are developed to reduce the velocity and depth of door intrusion into the passenger compartment in side impact crashes. Assessing the effectiveness of side impact beam is significant for reducing occupant fatalities and serious injuries.
In order to impove its side crashworthiness, a method using the hot formed side impact beam was proposed. The method produces the side impact beam with uniform thickness and varying yield strength by different cooling rate at hot forming. To make the distribution of the yield strength in the hot formed side impact beam reasonable, an optimization design was performed by the finite element analysis.
Ultra high strength steel was successfully produced by using hot stamping process. The microstructure of the samples was analyzed by microscope, and the tension strength and the hardness distribution of the samples were tested. The static character of side impact beam is analyzed by LS-DYNA through the interface of Hypermesh and LS-Prepost. The finite element model was built up according to FMVSS-214 and validated by the test data.
Based on the above results, an optimal distribution of the yield strength in the side impact beam material was obtained using the numerical optimization method of response surface and component collision simulation analysis. Before and after improvement simulation results show that the displacement, crashworthiness force and the effect of energy absorption are increase. The obtained results indicate that the crashworthiness of the front door and the whole car’s side can be improved by optimizing the side impact beam and finding the best distribution of material strength in certain range.
引文
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[5]龙江启,兰凤崇,陈吉清.车身轻量化与钢铝一体化结构新技术的研究进展[J].机械工程学报, 2008, 44(6): 27-35
[6]李淑慧,林忠钦,倪军等.拼焊板在车身覆盖件冲压成形中的研究进展[J].机械工程学报, 2002, 38(2): 1-7
[7] Hoffmann H, So H, Steinbeiss H. Design of hot stamping tools with cooling system[J]. CIRP Annals-Manufacturing Technology, 2007, 56(1): 269-272
[8] Merklein M, Lechler J. Investigation of the thermo-mechanical properties of hot stamping steels[J]. Journal of Materials Processing Technology, 2006, 177(1): 452-455
[9] Turetta A, Bruschi S, Ghiotti A. Investigation of 22MnB5 formability in hot stamping operations[J]. Journal of Materials Processing Technology, 2006, 177(1): 396-400
[10] Geiger M, Merklein M, Hoff C. Basic investigations on the hot stamping steel 22MnB5[J]. Advanced Material Research, 2005(6-8): 795-802
[11] Mori K, Saito S, Maki S. Warm and hot punching of ultra high strength steel sheet[J]. CRIP Annals-Manufacturing Technology, 2008, 57(1): 321-324
[12] Barcellona A, Palmeri D. Effect of plastic hot deformation on the hardness and continuous cooling transformations of 22MnB5 microalloyed boron steel[J]. Metallurgical and Material Transactions A, 2009, 40(5): 1160-1174
[13]林建平,王立影,田浩彬等.超高强度钢热流变行为[J].塑性工程学报, 2009, 16(2): 180-183
[14] Hardell J, Kassfeldt E, Prakash B. Friction and wear behavior of high strength boron steel at elevated temperatures of up to 800℃[J]. Wear, 2008, 264(9-10): 788-799
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