本文關(guān)鍵詞：多工位級進(jìn)模模具結(jié)構(gòu)偏載分析及優(yōu)化設(shè)計(jì)　出處：《華南理工大學(xué)》2016年碩士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： 多工位級進(jìn)模 級進(jìn)沖壓 偏載分析 拓?fù)鋬?yōu)化設(shè)計(jì) 結(jié)構(gòu)重構(gòu)

【摘要】：隨著高強(qiáng)板在汽車等行業(yè)內(nèi)的廣泛應(yīng)用,對多工位級進(jìn)模結(jié)構(gòu)強(qiáng)度的要求也越來越高。因高強(qiáng)板的屈服強(qiáng)度高、成形性能差,沖壓過程中大型多工位級進(jìn)模受力更加復(fù)雜惡劣,容易造成模具結(jié)構(gòu)偏載、損毀、失效等問題。因此,有必要針對大型多工位級進(jìn)模模具結(jié)構(gòu)進(jìn)行受力分析和結(jié)構(gòu)優(yōu)化設(shè)計(jì),特別是對于受側(cè)向力較明顯的凸模需進(jìn)行偏載分析,以判斷凸模側(cè)向位移是否會影響成形質(zhì)量。對于大型復(fù)雜多工位級進(jìn)模,工件尺寸大,沖孔、修邊、整形等工序的分布較分散,工作部分會采用組合子模的方式安裝在模具母體上,模具母體在沖壓過程中會產(chǎn)生較大的變形,嚴(yán)重影響工件的制造精度,造成產(chǎn)品沖壓質(zhì)量不穩(wěn)定,從而延長了修模試模的時(shí)間,繼而降低了模具的生產(chǎn)效率。因此,對多工位級進(jìn)模的母體進(jìn)行結(jié)構(gòu)分析,以保證模具強(qiáng)度、剛度、減小沖壓時(shí)模具結(jié)構(gòu)變形為目標(biāo)進(jìn)行優(yōu)化設(shè)計(jì),實(shí)現(xiàn)材料的最優(yōu)分布,達(dá)到模具結(jié)構(gòu)輕量化的效果,具有非常大的實(shí)用價(jià)值。本文以某油箱支架件為研究對象,通過對其多工位級進(jìn)沖壓成形及沖裁工序進(jìn)行數(shù)值模擬,獲得了板料與模具之間的接觸力,將該接觸力應(yīng)用至多工位級進(jìn)模結(jié)構(gòu)進(jìn)行受力分析,提取出側(cè)向力并進(jìn)行偏載分析,在此基礎(chǔ)上對模具母體結(jié)構(gòu)進(jìn)行拓?fù)鋬?yōu)化設(shè)計(jì)。研究內(nèi)容如下:(1)對某油箱支架結(jié)構(gòu)件多工位級進(jìn)沖壓成形工序進(jìn)行有限元數(shù)值模擬�；贑AE分析軟件Dynaform對成形工序進(jìn)行有限元建模,完成成形工序的數(shù)值模擬,通過對*dyn文件中的控制輸出文件進(jìn)行修改,獲得出板料上各節(jié)點(diǎn)的成形力模擬結(jié)果,并提取出凹凸模所受側(cè)向力信息。(2)對某油箱支架結(jié)構(gòu)件多工位級進(jìn)沖裁工序進(jìn)行有限元數(shù)值模擬�；贑AE分析軟件Deform-3D對沖裁工序進(jìn)行建模,建模時(shí)通過預(yù)先對板料刃口附近區(qū)域進(jìn)行網(wǎng)格細(xì)劃分、減小網(wǎng)格規(guī)模,獲得了準(zhǔn)確的模擬結(jié)果。完成了該油箱支架結(jié)構(gòu)件多工位級進(jìn)沖裁所有工序的數(shù)值模擬,得到了各個(gè)工序沖裁力的模擬結(jié)果,并與沖裁力的理論計(jì)算值進(jìn)行了對比分析,提取出沖裁工具與板料的接觸力。(3)針對沖壓過程中凹凸模受側(cè)向力作用,將數(shù)值模擬獲得的側(cè)向力作為力的邊界條件對凹凸模進(jìn)行偏載分析。利用結(jié)構(gòu)分析軟件HyperWorks對該多工位級進(jìn)模上模結(jié)構(gòu)和下模結(jié)構(gòu)進(jìn)行受力分析。借助本項(xiàng)目組自主開發(fā)的載荷映射工具,將沖壓載荷準(zhǔn)確映射到模具結(jié)構(gòu)分析有限元模型上。多工位級進(jìn)模的零部件數(shù)量多,結(jié)構(gòu)復(fù)雜,為提高運(yùn)算效率,可適當(dāng)簡化模型,如可將浮料板和氮?dú)鈴椈蛇M(jìn)行簡化。利用結(jié)構(gòu)分析求解器Radioss完成對模具結(jié)構(gòu)的受力分析。(4)基于變密度法對該油箱支架結(jié)構(gòu)件用大型多工位級進(jìn)模模具結(jié)構(gòu)進(jìn)行了拓?fù)鋬?yōu)化設(shè)計(jì)。根據(jù)結(jié)構(gòu)受力分析結(jié)果設(shè)定優(yōu)化目標(biāo),以減小模具變形為目的,實(shí)現(xiàn)材料的最優(yōu)分布�；谕�?fù)鋬?yōu)化結(jié)果,綜合考慮模具干涉、落料、加工制造等因素,在UG中對模具結(jié)構(gòu)進(jìn)行重構(gòu)。為了驗(yàn)證重構(gòu)后的模具結(jié)構(gòu)強(qiáng)度是否滿足要求,再次對重構(gòu)后的模具結(jié)構(gòu)進(jìn)行受力分析,并與原結(jié)構(gòu)變形量進(jìn)行對比。結(jié)果表明,優(yōu)化重構(gòu)后的模具結(jié)構(gòu)變形有所減小,模具減重約19%。(5)基于應(yīng)變電測法對模具結(jié)構(gòu)的應(yīng)變值進(jìn)行了取點(diǎn)測量,并與結(jié)構(gòu)分析模擬結(jié)果進(jìn)行了對比。結(jié)果表明,測量值與模擬結(jié)果的相對誤差普遍較小,相對誤差在10%以內(nèi)。因此,本文所采用的多工位級進(jìn)模結(jié)構(gòu)分析方法是準(zhǔn)確的,進(jìn)而保證了多工位級進(jìn)模結(jié)構(gòu)拓?fù)鋬?yōu)化結(jié)果的可靠性。
[Abstract]:With the wide application of high strength steel in automotive industry, the requirements of multi position progressive die structure strength is more and more high. Because of the high strength in high yield strength, poor formability, the stamping process of the large multi position progressive die stress more complex, easy to cause the mould structure of partial load, damage, failure so, it is necessary for large multi station progressive die structure stress analysis and structural optimization design, especially for the convex die under lateral force obviously require partial load analysis, to determine whether it will affect the lateral displacement of the punch forming quality. For large complex progressive die, the workpiece large size, punching, trimming, distribution is more dispersed shaping process, working parts using a combination of sub module is installed in the die, the die will produce large deformation during the stamping process, seriously affecting the workpiece precision manufacturing The degree of product quality is not stable, resulting in stamping, thus extending the model repaired time, then reduce the mold production efficiency. Therefore, analyzing the structure of the matrix of multi position progressive die, to ensure the mold strength, stiffness, reduce stamping die structure deformation for optimized design, to achieve the optimal distribution materials, achieve the lightweight mold structure effect, has great practical value. This paper takes a tank bracket as the research object, through the progressive stamping and blanking process by numerical simulation, obtained the contact force between the blank and die, the contact force applied at station level progressive die structure stress analysis, extraction and analysis of lateral force of eccentric load, on the basis of the die structure design of topology optimization. The contents are as follows: (1) of a fuel tank bracket structure progressive punching Pressure forming process numerical simulation by finite element analysis software Dynaform CAE. A finite element model of the forming process based on the complete numerical simulation of forming process, modified by controlling the output file of the *dyn file, get out of the forming force of each node of the sheet on the simulation results, and extract the die by lateral force information. (2) of a fuel tank bracket structure of progressive blanking process numerical simulation by finite element analysis software Deform-3D. CAE blanking process modeling based on modeling by pre on the sheet area near the edge of the grid partition, decreasing the grid size, obtain accurate simulation results. The numerical simulation of the fuel tank bracket structure of progressive blanking process all the simulation results are obtained in various processes of blanking force, and the calculated values were compared with the blanking force theory, extract The contact force of punching tool and sheet. (3) according to the stamping process of bump die under lateral force, the numerical simulation of lateral force obtained as force boundary conditions on the embossing die for partial load analysis. Using the software HyperWorks of the multi position progressive die mold structure and mold structure of the force analysis of structural analysis. With the help of load mapping tools developed by the project team, will load accurately mapped to the stamping die structure analysis on the finite element model. The parts multi position progressive die number, complex structure, in order to improve operation efficiency, may be appropriate to simplify the model, such as the floating plate and the nitrogen spring is simplified. Structure analysis of Radioss solver to analyze stress of die structure. (4) the variable density method of the fuel tank bracket structure for large multi station progressive die structure for topology optimization based on the design. According to the structure stress points The results of analysis to set the optimization goal, in order to reduce the mold deformation for the purpose of achieving the optimal distribution of materials. The results of topology optimization based on the comprehensive consideration of the mold interference, blanking, machining and other factors, to reconstruct the mold structure in UG. In order to verify the reconstructed mold structure strength meets the requirements of the mold structure reconstruction again after the stress analysis, and compared with the original structure deformation. The results show that the optimization of die structure reconstruction after deformation is reduced, the mold weight about 19%. (5) strain electrical measurement method of the die structure were taken based on the measurements and the simulation results are compared and analyzed. The results show that the structure the measurement value is generally small, the relative error of the simulated results with relative error less than 10%. Therefore, the multi position progressive die structure analysis method is accurate, and the multi position progressive die The reliability of the structural topology optimization results.

【學(xué)位授予單位】：華南理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2016
【分類號】：U466;TG385

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