卡車頂蓋論文中型卡車頂蓋沖壓成形數(shù)值模擬分析及其優(yōu)化

1、卡車頂蓋論文：中型卡車頂蓋沖壓成形數(shù)值模擬分析及其優(yōu)化【中文摘要】汽車整車的開發(fā)周期主要取決于其覆蓋件。由于汽車覆蓋件結(jié)構(gòu)復(fù)雜、制造精度及表面質(zhì)量要求極高,且其成形受很多因素的影響,僅靠工程師的設(shè)計(jì)經(jīng)驗(yàn)及傳統(tǒng)的“試錯法”很難獲得高質(zhì)量的產(chǎn)品,且開發(fā)周期長成本高。因此,應(yīng)用數(shù)值模擬及優(yōu)化技術(shù)對提高產(chǎn)品的設(shè)計(jì)質(zhì)量、縮短汽車的研制周期、降低生產(chǎn)成本、增強(qiáng)產(chǎn)品的市場競爭力等方面有著非凡的意義。本文以某中型卡車頂蓋為例,通過數(shù)值模擬及優(yōu)化技術(shù),探討其在成形過程中有可能會出現(xiàn)的質(zhì)量缺陷及解決方法,確定該頂蓋最優(yōu)的模具結(jié)構(gòu)及成形工藝為實(shí)際生產(chǎn)提供指導(dǎo)。本文基于板料成形基礎(chǔ)理論、沖壓數(shù)值模擬及優(yōu)化技術(shù),首先應(yīng)

2、用DYNAFORM軟件對頂蓋進(jìn)行沖壓成形的拉延、修邊及其回彈的數(shù)值模擬,分析了其板料的變形特點(diǎn)并研究了成形過程中有可能會出現(xiàn)的質(zhì)量問題及相關(guān)參數(shù)的影響(模具間隙、摩擦系數(shù)、壓邊力及拉延筋阻力)；然后,本文建立了成形質(zhì)量的多目標(biāo)模型并通過有限元模擬獲得了相應(yīng)的正交試驗(yàn)樣本,并在MATLAB軟件的環(huán)境下設(shè)計(jì)一個(gè)BP神經(jīng)網(wǎng)絡(luò)建立了各因素與成形質(zhì)量目標(biāo)函數(shù)間的非線性映射關(guān)系,并運(yùn)用多目標(biāo)遺傳算法進(jìn)行工藝參數(shù)優(yōu)化,確定一組最優(yōu)解集并在DYNAFORM中驗(yàn)證；最后,本文基于上述工作模擬了頂蓋的翻邊工序及其回彈,利用正交優(yōu)化獲得了相對最優(yōu)參數(shù)組合,并將此結(jié)果進(jìn)行了實(shí)驗(yàn)驗(yàn)證。通過數(shù)值模擬與試驗(yàn)對比分析發(fā)現(xiàn)：數(shù)

3、值模擬技術(shù)能預(yù)測成形缺陷,應(yīng)用正交設(shè)計(jì)及MATLAB優(yōu)化技術(shù)獲得的成形最優(yōu)工藝參數(shù)組合較為準(zhǔn)確,可以供生產(chǎn)實(shí)踐作為參考。該技術(shù)路線不僅顯著提高了工作效率,降低了生產(chǎn)成本,同時(shí)也提高了產(chǎn)品的質(zhì)量,值得在該領(lǐng)域推廣應(yīng)用。【英文摘要】The development cycle of a new type car mainly lies on its auto panels. It is very difficult to obtain high quality products only with empirical formula and traditional “trial and error

4、method” due to the complex auto panels, rigid manufacturer precision and surface quality of the auto panels and a lot of factors affecting its stamping forming process, in addition, the development cycle is long and its costs is very high. Therefore, the auto panels stamping forming simulation techn

5、ology has vital significance in cutting down auto manufacturing circle, reducing cost, improving design quality and enhancing market competitive ability.In this paper, taken a medium trucks roof panel for example, some researches in studying its quality problems and solutions during the roof panels

6、forming process was done by numerical simulation and optimization technology, and the best forming conditions which has reference significance to the actual production was selected out.Based on the basal theory of sheet metal forming, simulation technology and optimization technology was researched

7、in this paper. Firstly, using numerical simulation in drawing forming and trimming process and its spring-back, a medium trucks roof panel was taken into account to obtain the deformation characteristics of the blank and study the quality problems that may appear in the forming process and the impac

8、t of the parameters (gap between die and punch, friction modulus, blank holder force and draw-bead resistance); Secondly, this paper set up a multi-objective model between its impact factors and forming quality and obtained corresponding orthogonal samples by finite element method. It also built a n

9、on-linear mapping between its impact factors and forming quality by designing a BP neural network in MATLAB software, and then obtained an optimized set of impact factors in the forming process by multi-objective genetic algorithm; Finally, based on the above work, the numerical simulation in flangi

10、ng process and its spring-back was researched, and the optimized parameter combination was determined by orthogonal experiment and the results was verified at last.The results by contrast show that numerical simulation can forecast the forming defects, and the optimized parameter combination obtaine

11、d by orthogonal experiment and MATLAB optimization technology is exact. The optimization results can guide the actrol production. The technology course can not only increase the work efficiency greatly and reduce the production costs but also improve the quality of products, the popularization and applicatio