基于特征的冲压件快速成形仿真软件的开发
摘要
本文围绕基于特征的冲压件快速成形仿真软件的开发工作展开。涉及的内容有一步逆成形有限元法的基本理论,特征技术,在UG/NX6开发平台下开发的One-step Formability Analysis软件的界面及其功能,基于特征开发的功能模块,以及对软件进行了实例验证。
本文介绍了在UG/NX6开发平台上One-step Formability Analysis软件的UI主界面、参数设置界面和约束设置界面及其功能;叙述了前处理中新添加的指定回弹评定点、网格质量检查等功能;以回弹facet body显示云图为例,介绍了后处理的显示功能。
本文重点介绍One-step Formability Analysis软件的特征功能模块的开发,给出了程序流程图,叙述了特征功能的实现过程,并给出了实例演算。
最后,本文以典型算例说明One-step Formability Analysis软件具有CAD与CAE无缝集成;支持基于物理迭代的钣金件展开、基于空间的曲面展开和空间分离部件展开的功能与特点。
During the automotive design and manufacture period, it is the main factor of auto product development speed and quality that the design and manufacture level of the auto body die especially auto panel die.
The work of the present paper is finished based on development of One-step Formability Analysis (integration product of Kmas/One-Step solver with UG/NX) with support of National Vehicle Electrical Industry High-tech Project“CAD/CAE/CAM software platform for digital lean design and manufacturing of auto-body part”(Project No.: Department of High-tech industry of National Development and Reform Commission 2040) and commission project of UGS PLM Solutions company’s software functionality development (Project ID 901PC). This paper mainly finishes key development technique, functionality and solution of One-Step Formability Analysison UG/NX6; and development the feature function of One-Step Formability Analysis.
One-step Formability Analysis, software is developed based on UG/NX6. It utilizes UG’s newest user interface technique and internal code to complete pre-processor, post-processor and UI design, then integrates Kmas/One-Step solver by invoking its dynamic link libraries. By the two issues, it implements all the functionalities of formability analysis software, including UI, pre-processor, post-processor and solver. The pre-processor achieves closer integration between CAD and CAE software. After selecting un-form region, boundary conditions, draw directions and pushing“Mesh”button in CAD mode of preprocess, the application would enter CAE mode to create mesh, read mesh datum, and then return back to CAD mode to do calculation and display result. Both entering CAE interface and going back to CAD interface are completed automatically in the application and not needed for manually operation of users. In pre-processor, the use of the former feature technology is for the realization of CAE parameters of operation, that is, when the CAD model of the system has changed, that of the corresponding system CAE converse at the same time.
One-step Formability Analysis could work under two modes: un-form and intermediate un-form, which offer potent tool for the designer of the pressing die and progressive die. The application scope of that is not only limited to the tamping parts and die designs of automotive industry , can but also provide effective support to the product design and industry analysis of sheet metal stamping parts on electronics, household widely appliances.
Besides, the One-step Formability Analysis which based on feature offer following enhanced functions:
λIn the constraint, the user can specify three springback match points for springback assessment. In the actual production of pressing on the springback of the measurement method is to make the three points of pressing part rely on the same standard components respective and three springback become 0 points, followed by measuring the resilience of other points . Now, after adding a user input rebound assessed match point interface, the output will be more in line with the actual work.
λProvided quality checks for input mesh. Before computing by solver, quality of mesh should be checked. If the quality of mesh can meet the requirements, then do the calculation, otherwise feed back the user corresponding information and re-transmission mesh is required. Quality of mesh determines the quality and efficiency of solver directly. Poor quality of input mesh often leads to much longer calculating, inaccuracies of results, even failure which is wasting time of users. This function improves efficiency of the work and accuracy of the solution.
λIntermediate un-form supports that of separate parts. The two parts could flatten on the target region,or one part flattens on the region of another part. That could compare the flattening shapes. Have some practical significance.
λSpringback displayed change from single nephogram to display two ways of the nephogram and output the facetbody of UG . When users computed springback, they not only concerned about the greatest resilience of the part, but also wish to get the specific shape of the part after doing springback. Adding the output of facetbody , the user can obtain the model of the parts after springback computing through facetbody, and then use for the follow-up analysis, optimization.
λAdding the attributes of the feature. The One-step Formability Analysis software can not only preserve the results of this set of parameters, information of mesh and calculation information in the analysis of the document , but also record the un-form region, constraint curves, materials and other parameters, moreover edit this information.
本文介绍了在UG/NX6开发平台上One-step Formability Analysis软件的UI主界面、参数设置界面和约束设置界面及其功能;叙述了前处理中新添加的指定回弹评定点、网格质量检查等功能;以回弹facet body显示云图为例,介绍了后处理的显示功能。
本文重点介绍One-step Formability Analysis软件的特征功能模块的开发,给出了程序流程图,叙述了特征功能的实现过程,并给出了实例演算。
最后,本文以典型算例说明One-step Formability Analysis软件具有CAD与CAE无缝集成;支持基于物理迭代的钣金件展开、基于空间的曲面展开和空间分离部件展开的功能与特点。
During the automotive design and manufacture period, it is the main factor of auto product development speed and quality that the design and manufacture level of the auto body die especially auto panel die.
The work of the present paper is finished based on development of One-step Formability Analysis (integration product of Kmas/One-Step solver with UG/NX) with support of National Vehicle Electrical Industry High-tech Project“CAD/CAE/CAM software platform for digital lean design and manufacturing of auto-body part”(Project No.: Department of High-tech industry of National Development and Reform Commission 2040) and commission project of UGS PLM Solutions company’s software functionality development (Project ID 901PC). This paper mainly finishes key development technique, functionality and solution of One-Step Formability Analysison UG/NX6; and development the feature function of One-Step Formability Analysis.
One-step Formability Analysis, software is developed based on UG/NX6. It utilizes UG’s newest user interface technique and internal code to complete pre-processor, post-processor and UI design, then integrates Kmas/One-Step solver by invoking its dynamic link libraries. By the two issues, it implements all the functionalities of formability analysis software, including UI, pre-processor, post-processor and solver. The pre-processor achieves closer integration between CAD and CAE software. After selecting un-form region, boundary conditions, draw directions and pushing“Mesh”button in CAD mode of preprocess, the application would enter CAE mode to create mesh, read mesh datum, and then return back to CAD mode to do calculation and display result. Both entering CAE interface and going back to CAD interface are completed automatically in the application and not needed for manually operation of users. In pre-processor, the use of the former feature technology is for the realization of CAE parameters of operation, that is, when the CAD model of the system has changed, that of the corresponding system CAE converse at the same time.
One-step Formability Analysis could work under two modes: un-form and intermediate un-form, which offer potent tool for the designer of the pressing die and progressive die. The application scope of that is not only limited to the tamping parts and die designs of automotive industry , can but also provide effective support to the product design and industry analysis of sheet metal stamping parts on electronics, household widely appliances.
Besides, the One-step Formability Analysis which based on feature offer following enhanced functions:
λIn the constraint, the user can specify three springback match points for springback assessment. In the actual production of pressing on the springback of the measurement method is to make the three points of pressing part rely on the same standard components respective and three springback become 0 points, followed by measuring the resilience of other points . Now, after adding a user input rebound assessed match point interface, the output will be more in line with the actual work.
λProvided quality checks for input mesh. Before computing by solver, quality of mesh should be checked. If the quality of mesh can meet the requirements, then do the calculation, otherwise feed back the user corresponding information and re-transmission mesh is required. Quality of mesh determines the quality and efficiency of solver directly. Poor quality of input mesh often leads to much longer calculating, inaccuracies of results, even failure which is wasting time of users. This function improves efficiency of the work and accuracy of the solution.
λIntermediate un-form supports that of separate parts. The two parts could flatten on the target region,or one part flattens on the region of another part. That could compare the flattening shapes. Have some practical significance.
λSpringback displayed change from single nephogram to display two ways of the nephogram and output the facetbody of UG . When users computed springback, they not only concerned about the greatest resilience of the part, but also wish to get the specific shape of the part after doing springback. Adding the output of facetbody , the user can obtain the model of the parts after springback computing through facetbody, and then use for the follow-up analysis, optimization.
λAdding the attributes of the feature. The One-step Formability Analysis software can not only preserve the results of this set of parameters, information of mesh and calculation information in the analysis of the document , but also record the un-form region, constraint curves, materials and other parameters, moreover edit this information.
引文
1. 国家发展和改革委员会,汽车产业发展政策,2004.6. 1。
2. 环商数据 2007年中国汽车产量888.24万 2008.1.16 http://www.worldbydata.com/fenx/fenxview-12238.htm
3. 中国汽车工业协会 2008.1.17 http://www.catarc.ac.cn/ac/hydt/webinfo/2008-01-17/1196727134182098.htm
4. 中国汽车工业协会统计信息网 中汽协会:2007年轿车市场分析 2008.1.25 http://www.auto-stats.org.cn/ReadArticle.asp?NewsID=5036
5. Hallquist, J. O., NIKE2D An implicit finite deformation finite element code for analysis the static and dynamic response of two-dimension solids, University of California, Lawerence Livemore National Lab. Report, 1979.
6. Karlsson and Sorensen, Inc., ABAQUS, User’s Manual, Providence, 1989.
7. Surana, K. S., Lumped mass matrices with non-zero inertia for general shell and axisymmetric shell element, Int. J. Num. Meths. Engng., 1978, 12: 1635-1650.
8. Hughes, T. J. R. and Taylar, R. L., A simple and efficient finite element for plates bending, Int. J. Num. Meths. Engng., 1981, 11: 679-706.
9. 童春桥 板材成形CAE技术及其应用 《CAD/CAM与制造业信息化》 2005
10. 韩同群,车用内燃机设计与CAD/CAE集成技术综述,农业装备与车辆工程,2006,6:37-42。
11. 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,机电工程技术,第33卷,2004,5:13-15。
12. 吉林大学宣传部,由我校完全自主研发的汽车车身部件快速一步成形分析仿真商品化软件获得成功,2006.8.23 http://www.jlu.edu.cn/news/new/php/view.php?id=2844
13. 韩玲莉,黄俊 基于特征建模技术的CAD/CAE集成方法研究 机械设计与研究 第22卷第6期 2006.12
14. 周受钦,谢友柏 特征及其应用 西安交通大学润滑理论及轴承研究所
15. 陈积光 特征技术及其展望 广西民族学院学报 第5卷第1期 1999年2月
16. 张志刚,曹西京 基于特征的建模技术 机械研究与应用 第17卷第5期,2004.10
17. 姜 华,基于KBE的交叉臂式车门玻璃升降器参数化建模技术及软件开发,吉林大学硕士学位论文,2005
18. Alex Pabiadzimski, Machael T.Reger. Unified Development Unit User Guide. EDS/PLM Solution. 2003.04.
19. 董正卫,田立中,付宜利,UG/OPEN API编程基础,清华大学出版社,2002
20. 王自勤 计算机辅助工程(CAE)技术及其应用 贵州工业大学学报 第30卷第4期
21. 韩玲莉,黄俊 基于特征建模技术的CAD/CAE集成方法研究 机械设计与研究 第22卷第6期 2006.12
22. 胡 平 柳玉起 王锦程 李运兴 那景新 杨 光 吴志强 郭 威 张向奎, 板材冲压成形性模拟CAE 软件系统KMAS
23. 姜 华,基于 KBE 的交叉臂式车门玻璃升降器参数化建模技术及软件开发,吉林大学硕士学位论文 2005
24. 马幼鸣 潘旭峰 陈思忠 谷中丽 乔念东 , 车身覆盖件虚拟制造系统的开发与研究 , 《机械工业自动化》
25. 博 西 华 家 用 电 器 有 限 公 司 TR 小 组 UG 在 产 品 研 发 中 的 应 用 http://www.moldbbs.com/Announce/Announce.asp?BoardID=8&ID=10211
26. 南昌凯马柴油机有限公司 黄有华 UG NX3 三维 CAD 应用于产品设计, http://www.0769.net.cn/news/shownews.asp?newsid=2069
27. William F. Hosford, Influence of Textures on Sheet Forming, SAE TECHNICAL PAPER SERIES 2000-01-0771
28. Andrew Chadwick Kevin Garry Jeff Howell, Transient Aerodynamic Characteristics of Simple Vehicle Shapes by the Measurement of Surface Pressures, SAE TECHNICAL PAPER SERIES 2001-01-0876
29. Daniel Heiserer1, Mladen Chargin,Design Study for Problems Involving Responses over Multiple Disciplines
30. Xiong Jian, Bin Qin, Yongqian Xiong, Dezhi Chen, Tiaoqin Yu, Mingwu Fan ,MODELING AND BEAM DYNAMIC VISUALIZATION IN CYCLOTRON VIRTUAL PROTOTYPING,Proceedings of the 2003 Particle Accelerator Conference
31. Ding, Yi , Studies of Methodology for Conceptual Auto-Body Design Using KBE and DFM Techniques and Development of the Special-Purpose ICAD Software
32. EDS Corp.,products_NX2
33. EDS Corp.,products_UG_NX
34. MSC.visualNastran,virtual_manufacturing
35. Jiun-Shyan Chen Hui-Ping Wang,Meshfree Smooth Surface Contact Algorithm For Sheet Metal Forming
36. Kuo-Kuang Chen,WRAPFORM-II: A New Binder Forming Simulation Method,SAE TECHNICAL PAPER SERIES 2000-01-1106
37. Sing C. Tang,Trends on Simulation of Sheet Metal Forming Processes,SAE TECHNICAL PAPER SERIES 2000-01-1108
38. J. L. Sullivan, M. M. Costic and W. Han ,Automotive Life Cycle Assessment: Overview, Metrics, and Examples,SAE TECHNICAL PAPER SERIES 980467
39. Jason J. Tao and Todd A. Bishop,System Modeling of A Damper Module,SAE TECHNICAL PAPER SERIES 2000-01-0727
40. Philip R. de Vos,Modelling of Two-Phase Direct Cylinder Injection,SAE TECHNICAL PAPER SERIES 2000-01-1393
41. Matthias Finkbeiner, Klaus Ruhland, Halil Cetiner, Marc Binder and BrunoStark,Life Cycle Engineering as a Tool for Design for Environment,SAE TECHNICAL PAPER SERIES 2000-01-1491
42. David D Ward Ian R Kendall,Automotive Software Engineering Using the MISRA Guidelines,SAE TECHNICAL PAPER SERIES 2000-01-0715
43. 彭岳华 盛治华,基于 UG 软件开发平台的汽车产品开发,计算机辅助工程,N o. 3 Sept.2002
44. 闫康康,郭 威,申国哲,胡 平,基于KMAS的国际板成形Benchmark试验研究
45. Erik Hollander and Inger Jansson , Long Term Mechanical and Environmental Properties of Adhesive Intensive Car Body,1999-01-3200
46. Pingsha Dong (Xin Sun, Feng Lu and Jinmiao Zhang), A Framework for Modeling Spot Welds in Finite Element Analysis of Auto-Body Structures,1999-01-3191
47. Luis German, Joel P. Clark, Richard Roth, Economic Analysis of Hydro-Mechanical Sheet Metal Forming, 1999-01-3207
48. Oliver Bandte, Dimitri N. Mavris and Daniel A. DeLaurentis, Viable Designs Through a Joint Probabilistic Estimation Technique, 1999-01-5623
49. Takeshi Abe, Bruce Bonhard, Ming-Te Cheng, Mark Bosca,Chris Kwasniewicz and Liquin Na, High Frequency Gear Whine Control by Driveshaft Design Optimization, SAE TECHNICAL PAPER SERIES 2003-01-1478
50. Sanjay K. Mahajan, Matthew M. Surella and Thomas C. Single, Designing Six Sigma Quality into a RWD IRS Driveline System for Improved Vehicle-Level NVH Performance, SAE TECHNICAL PAPER SERIES 2003-01-1494
51. Mark Allman-Ward, Joe Venor, Roger Williams, Martin Cockrill, Hartwig Distler, Alun Crewe and Thorsten Heinz, The Interactive NVH Simulator as a Practical Engineering Tool, SAE TECHNICAL PAPER SERIES 2003-01-1505
52. E. Y. Kuo, Up-Front Body Structural Designs for Squeak and Rattle Prevention, SAE TECHNICAL PAPER SERIES 2003-01-1523
53. S. Subramanian, R. Surampudi, K. R. Thomson and S. Vallurupalli, Optimization of Damping Treatment for Structure Borne Noise Reduction, SAE TECHNICAL PAPER SERIES 2003-01-1592
54. Leon Leventhal, CAE Applications in Hydraulics — Experimental and Analytical Study of a Check-Valve, SAE TECHNICAL PAPER SERIES 2003-01-1605
55. Ji-Un Lee, Jin-Kwan Suh, Seung-Kab Jeong, Satish Kandarpa, Aqil Ahsan and Walter L. Wolf, Development of Input Loads for Road Noise Analysis SAE TECHNICAL PAPER SERIES 2003-01-1608
56. Ming-Ran Lee, Mark McCarthy, Martin Romzek, Tom Frei and Ya-Juan Bemman, Exhaust System Design for Sound Quality, SAE TECHNICAL PAPER SERIES 2003-01-1645
57. Asif Rohilla and Mohamad Qatu, Finite Element Vibration Studies of As-Installed Power Steering Pumps, SAE TECHNICAL PAPER SERIES 2003-01-1671
58. Luiz Vieira Morgado and Luciano Santos Driemeier, Use of CFD to Support Heat Management CAE Simulation, SAE TECHNICAL 2003-01-3559 PAPER SERIES E
59. Odilon Terreri Perseguim, Eduardo Peres and Claudio Gomes Fernandes, Pickups Vehicle Dynamics: Ride and Skate, SAE TECHNICAL 2003-01-3588 PAPER SERIES E
60. Joselito Menezes da Cruz, Ivan Lima do Espirito Santo and Adilson Aparecido de Oliveira , A Semi-Analytical Method to Generate Load Cases For CAE Durability Using Virtual Vehicle Prototypes, SAE TECHNICAL 2003-01-3667 PAPER SERIES E
61. 王洪俊,那景新,李大永 汽车覆盖件模具CAD技术的应用与发展
2. 环商数据 2007年中国汽车产量888.24万 2008.1.16 http://www.worldbydata.com/fenx/fenxview-12238.htm
3. 中国汽车工业协会 2008.1.17 http://www.catarc.ac.cn/ac/hydt/webinfo/2008-01-17/1196727134182098.htm
4. 中国汽车工业协会统计信息网 中汽协会:2007年轿车市场分析 2008.1.25 http://www.auto-stats.org.cn/ReadArticle.asp?NewsID=5036
5. Hallquist, J. O., NIKE2D An implicit finite deformation finite element code for analysis the static and dynamic response of two-dimension solids, University of California, Lawerence Livemore National Lab. Report, 1979.
6. Karlsson and Sorensen, Inc., ABAQUS, User’s Manual, Providence, 1989.
7. Surana, K. S., Lumped mass matrices with non-zero inertia for general shell and axisymmetric shell element, Int. J. Num. Meths. Engng., 1978, 12: 1635-1650.
8. Hughes, T. J. R. and Taylar, R. L., A simple and efficient finite element for plates bending, Int. J. Num. Meths. Engng., 1981, 11: 679-706.
9. 童春桥 板材成形CAE技术及其应用 《CAD/CAM与制造业信息化》 2005
10. 韩同群,车用内燃机设计与CAD/CAE集成技术综述,农业装备与车辆工程,2006,6:37-42。
11. 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,机电工程技术,第33卷,2004,5:13-15。
12. 吉林大学宣传部,由我校完全自主研发的汽车车身部件快速一步成形分析仿真商品化软件获得成功,2006.8.23 http://www.jlu.edu.cn/news/new/php/view.php?id=2844
13. 韩玲莉,黄俊 基于特征建模技术的CAD/CAE集成方法研究 机械设计与研究 第22卷第6期 2006.12
14. 周受钦,谢友柏 特征及其应用 西安交通大学润滑理论及轴承研究所
15. 陈积光 特征技术及其展望 广西民族学院学报 第5卷第1期 1999年2月
16. 张志刚,曹西京 基于特征的建模技术 机械研究与应用 第17卷第5期,2004.10
17. 姜 华,基于KBE的交叉臂式车门玻璃升降器参数化建模技术及软件开发,吉林大学硕士学位论文,2005
18. Alex Pabiadzimski, Machael T.Reger. Unified Development Unit User Guide. EDS/PLM Solution. 2003.04.
19. 董正卫,田立中,付宜利,UG/OPEN API编程基础,清华大学出版社,2002
20. 王自勤 计算机辅助工程(CAE)技术及其应用 贵州工业大学学报 第30卷第4期
21. 韩玲莉,黄俊 基于特征建模技术的CAD/CAE集成方法研究 机械设计与研究 第22卷第6期 2006.12
22. 胡 平 柳玉起 王锦程 李运兴 那景新 杨 光 吴志强 郭 威 张向奎, 板材冲压成形性模拟CAE 软件系统KMAS
23. 姜 华,基于 KBE 的交叉臂式车门玻璃升降器参数化建模技术及软件开发,吉林大学硕士学位论文 2005
24. 马幼鸣 潘旭峰 陈思忠 谷中丽 乔念东 , 车身覆盖件虚拟制造系统的开发与研究 , 《机械工业自动化》
25. 博 西 华 家 用 电 器 有 限 公 司 TR 小 组 UG 在 产 品 研 发 中 的 应 用 http://www.moldbbs.com/Announce/Announce.asp?BoardID=8&ID=10211
26. 南昌凯马柴油机有限公司 黄有华 UG NX3 三维 CAD 应用于产品设计, http://www.0769.net.cn/news/shownews.asp?newsid=2069
27. William F. Hosford, Influence of Textures on Sheet Forming, SAE TECHNICAL PAPER SERIES 2000-01-0771
28. Andrew Chadwick Kevin Garry Jeff Howell, Transient Aerodynamic Characteristics of Simple Vehicle Shapes by the Measurement of Surface Pressures, SAE TECHNICAL PAPER SERIES 2001-01-0876
29. Daniel Heiserer1, Mladen Chargin,Design Study for Problems Involving Responses over Multiple Disciplines
30. Xiong Jian, Bin Qin, Yongqian Xiong, Dezhi Chen, Tiaoqin Yu, Mingwu Fan ,MODELING AND BEAM DYNAMIC VISUALIZATION IN CYCLOTRON VIRTUAL PROTOTYPING,Proceedings of the 2003 Particle Accelerator Conference
31. Ding, Yi , Studies of Methodology for Conceptual Auto-Body Design Using KBE and DFM Techniques and Development of the Special-Purpose ICAD Software
32. EDS Corp.,products_NX2
33. EDS Corp.,products_UG_NX
34. MSC.visualNastran,virtual_manufacturing
35. Jiun-Shyan Chen Hui-Ping Wang,Meshfree Smooth Surface Contact Algorithm For Sheet Metal Forming
36. Kuo-Kuang Chen,WRAPFORM-II: A New Binder Forming Simulation Method,SAE TECHNICAL PAPER SERIES 2000-01-1106
37. Sing C. Tang,Trends on Simulation of Sheet Metal Forming Processes,SAE TECHNICAL PAPER SERIES 2000-01-1108
38. J. L. Sullivan, M. M. Costic and W. Han ,Automotive Life Cycle Assessment: Overview, Metrics, and Examples,SAE TECHNICAL PAPER SERIES 980467
39. Jason J. Tao and Todd A. Bishop,System Modeling of A Damper Module,SAE TECHNICAL PAPER SERIES 2000-01-0727
40. Philip R. de Vos,Modelling of Two-Phase Direct Cylinder Injection,SAE TECHNICAL PAPER SERIES 2000-01-1393
41. Matthias Finkbeiner, Klaus Ruhland, Halil Cetiner, Marc Binder and BrunoStark,Life Cycle Engineering as a Tool for Design for Environment,SAE TECHNICAL PAPER SERIES 2000-01-1491
42. David D Ward Ian R Kendall,Automotive Software Engineering Using the MISRA Guidelines,SAE TECHNICAL PAPER SERIES 2000-01-0715
43. 彭岳华 盛治华,基于 UG 软件开发平台的汽车产品开发,计算机辅助工程,N o. 3 Sept.2002
44. 闫康康,郭 威,申国哲,胡 平,基于KMAS的国际板成形Benchmark试验研究
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