CN111539145A - Optimization method of compression molding die for automobile hat rack - Google Patents
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Abstract
The invention relates to the field of mold design, in particular to an optimization method of a compression molding mold for an automobile hat rack, which comprises the following steps: carrying out process numerical simulation on the compression molding process of the hat rack by using a structural analysis nonlinear finite element program to obtain node force information of the male die and the female die; constructing a topological optimization boundary condition of the punch-die structure by using a load mapping method; carrying out topological optimization iterative solution on the male-female die structure by using finite element structure analysis and optimization software; according to the final appearance of the topological optimization of the structure of the punch-die, the structure of the punch-die is improved by using three-dimensional software; the invention greatly reduces the weight of the die and the production cost on the premise of meeting the structural rigidity and the strength of the die.
Description
Technical Field
The invention relates to the field of mold design, in particular to an optimization method of a compression molding mold for an automobile hat rack.
Background
With the increase of economy, the automobile industry in China is rapidly developed, the automobile maintenance amount is promoted year by year, people pay more and more attention to the interior trim quality of the automobile while pursuing beautiful automobile body appearance and surge power, and the automobile interior trim becomes an important factor for measuring the grade of the automobile. With the rapid development of decades, automotive interior parts have been gradually developed from the original basic driving and riding environment for drivers and passengers to humanized high-value-added products combining design aesthetics and ergonomics. Automotive interior development has become an important issue next to automotive body development.
The compression molding is used as a main molding process of the automotive interior product, and has wide application prospect. In the design of the compression molding die for the automobile hat rack main body, the design of a punch and a die is crucial as a part for directly molding a product, and designers are often conservative in order to ensure the rigidity and the strength of the punch and the die and leave a large safety margin, so that the die is large in quality and has no scientificity. The designed die not only meets the requirement of producing qualified molded parts, but also considers the factors of processing and manufacturing, tonnage of the press, energy consumption and the like, thereby achieving the aims of convenient use and cost reduction.
At present, lightweight design of a mold and the like are development directions of mold optimization. By combining the past design experience and utilizing a CAE tool which is continuously developed and advanced, the structure of the die is analyzed and optimally designed before the die is machined, and scientific guidance can be provided for the die design.
For example, chinese patent CN201810840439.3 discloses a method, system, apparatus and storage medium for optimizing the dimensions of a mold precursor, the optimizing method comprising: the method comprises the steps of obtaining actual size parameters of a die matrix and contact force between the die matrix and a blank in a stamping process, obtaining simulation size parameters of a simulation die according to the actual size parameters and the contact force, screening the simulation size parameters meeting preset conditions, outputting the simulation size parameters as optimization results, and optimizing the size of the die matrix under the condition that the deformation of the die matrix meets constraint conditions, so that the size of the die matrix is the minimum, the weight of the die matrix is reduced, meanwhile, the rigidity of the die is improved through an optimization algorithm, and under the condition that a topological structure is fixed and does not change working conditions, the size of the die matrix is optimized, and light weight is achieved.
At present, the invention provides a lightweight optimization method for a compression molding die for interior trim parts, aiming at the problem of overweight die quality caused by empirical design of the compression molding die for the interior trim parts of the automobile.
Disclosure of Invention
The technical problem to be solved by the invention is to provide an optimization method of a compression molding die for an automobile hat rack, which greatly reduces the weight of the die and the production cost on the premise of meeting the structural rigidity and strength of the die.
In order to solve the technical problems, the invention provides the following technical scheme:
an optimization method of a compression molding die for an automobile hat rack is applied to a punch-die for optimizing a compression molding process of the hat rack, and comprises the following steps:
step two, carrying out process numerical simulation on the compression molding process of the hat rack by using a structural analysis nonlinear finite element program to obtain node force information of the male die and the female die;
thirdly, constructing a topological optimization boundary condition of the male-female die structure by using a load mapping method;
step four, carrying out topological optimization iterative solution on the male and female die structures by using finite element structure analysis and optimization software;
and step five, improving the structure of the punch-die by using three-dimensional software according to the final shape of the topological optimization of the structure of the punch-die.
Preferably, before the second step, the following steps are further included:
step one, designing a compression molding punch-die structure.
Preferably, the step one specifically comprises the following steps:
step 1.1, obtaining the average shrinkage rate of the composite structure through experiments and calculation;
and 1.2, compensating and calculating the shrinkage rate of the product during solidification and cooling by adopting an error compensation mode.
Preferably, the process numerical simulation in the second step specifically includes the following steps:
step 2.1, carrying out meshing division, heat transfer model setting, contact and friction setting, hourglass control, energy dissipation control and time step control;
2.2, inputting the composite material and the parameters of the male die and the female die set in the first step;
and 2.3, acquiring the node force information of the male die and the female die through simulation calculation.
Preferably, the grid division specifically uses swept grid division, and the grid is divided by SOLID168 units.
Preferably, the composite material adopts shell163 thin shell units, and the sheet grid is a regular quadrilateral unit.
Preferably, the simulation calculation uses the Belytschko-Tsay algorithm.
Preferably, the step four specifically comprises the following steps:
step 4.1, establishing a structural topology optimization model of the punch-die;
and 4.2, topologically optimizing the structure of the male die and the female die. Preferably, step 4.2 specifically comprises the following steps:
step 4.2.1, setting an optimization variable;
step 4.2.2, defining an optimization target and constraint conditions;
and 4.2.3, calculating and obtaining a topology optimization result.
Preferably, the sixth step specifically comprises the following steps:
step 6.1, exporting a universal model file by using a finite element structure analysis and optimization software program, and importing the universal model file into three-dimensional software;
and 6.2, reversely drawing the die male and female die structure by using three-dimensional software, thereby obtaining the topologically optimized male and female die structure.
Compared with the prior art, the invention has the beneficial effects that:
the invention uses a structural analysis nonlinear finite element program to simulate the compression molding process of the automobile hat rack main body, obtains the node force information with large deformation in the stress concentration area of the mold under the actual working condition, takes load mapping as the boundary condition of the topology optimization of the mold, then establishes a material interpolation optimization mathematical model of a punishment model of solid isotropic materials of a female mold and a male mold, and adopts finite element structural analysis and optimization software to carry out lightweight design on the male and female molds of the compression molding mold of the automobile hat rack main body based on a variable density method, thereby greatly reducing the weight of the mold and reducing the production cost on the premise of meeting the structural rigidity and strength of the mold.
Figure illustrates the drawings
FIG. 1 is a top view of a hatrack of the present invention;
FIG. 2 is a perspective view of the female mold of the present invention;
FIG. 3 is a perspective view of the male of the present invention;
FIG. 4 is a grid division diagram of the present invention;
FIG. 5 is a flowchart of topology optimization of the present invention;
FIG. 6 is a graph of the punch displacement calculation results of the present invention;
FIG. 7 is a graph of the calculated equivalent stress for a male die of the present invention;
FIG. 8 is a graph of the die displacement calculation results of the present invention;
FIG. 9 is a graph of the calculated results of the equivalent stress of the female die of the present invention;
FIG. 10 is a cloud of the terrace die topology of the invention;
FIG. 11 is a cloud of the topological profile of the female mold of the present invention;
FIG. 12 is a perspective view of the male die of the present invention after optimization;
FIG. 13 is a perspective view of the female mold of the present invention after it has been optimized;
FIG. 14 is a flow chart of the operation of the present invention;
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "front", "rear", "vertical", "horizontal", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
An optimization method of a compression molding die for an automobile hat rack is applied to a punch-die for optimizing a compression molding process of the hat rack, and comprises the following steps:
step one, designing a compression molding punch-die structure.
According to designing the task book according to the mould, design according to traditional mould design criterion and go out the die structure of compression moulding, it is specific: firstly, establishing a model of the automobile hat rack shown in figure 1 by using three-dimensional software; then, the mold is split according to the central surface, and the male and female mold surfaces shown in fig. 2 and 3 are obtained by respectively offsetting the upper and lower parts by half the wall thickness.
Step two, carrying out process numerical simulation on the compression molding process of the hat rack by using a structural analysis nonlinear finite element program (LS-DYNA finite element program) to obtain node force information of the male die and the female die;
thirdly, constructing a topological optimization boundary condition of the male-female die structure by using a load mapping method;
step four, carrying out topological optimization iterative solution on the male-female die structure by using finite element structure analysis and optimization software (OptiStruct);
and step five, improving the structure of the punch and die by using three-dimensional software (CATIA) according to the final appearance of the topological optimization of the structure of the punch and die.
The first step specifically comprises the following steps:
step 1.1, obtaining the average shrinkage rate of the composite structure through experiments and calculation;
and 1.2, compensating and calculating the shrinkage rate of the product during solidification and cooling by adopting an error compensation mode.
The composite material can be solidified and shrunk, the size of a product can be reduced during the solidification and molding process or after the solidification and molding process, the shrinking proportion is the shrinkage rate, in order to avoid that the size of the product is smaller than the design size after the product is solidified and cooled, the shape of the mold needs to be compensated and calculated according to the shrinkage rate of the product when the mold is designed, and the size of the product is close to the design size after the product is solidified, molded and shrunk.
Shrinkage is an inherent characteristic of a composite material product, is influenced by factors such as the wall thickness of a workpiece, forming process conditions and the like, is selected by experience based on factory practice, and is difficult to accurately determine the shrinkage mainly because:
first, the shrinkage rates of various materials given by material suppliers are a range and not a fixed value, because the shrinkage rates of the same material produced by different factories are different, even if the shrinkage rates of the same material produced by different batches of one factory are different; secondly, the automobile hat rack main body is formed by compounding a GMT sheet and a needle-punched PET fabric, and the shrinkage rate of the compound two-layer structure cannot be accurately estimated.
Therefore, the molding shrinkage of the product is measured by adopting a test mode, and the test process is as follows:
GMT plates with the glass fiber content of 4.5mm in thickness being 30% and needled PET fabrics with the thickness of 1.5mm are selected for 20 pieces respectively, and in the experiment, the preheating time, the pressure maintaining time, the forming pressure and the mold closing speed of the sheets adopt standard production process parameters. And (3) after the mould is opened, immediately measuring the distance between the selected positions, measuring one position of each piece in the length and width directions, standing the product at room temperature for 24 hours, measuring the selected positioning point again, and finally calculating by using a formula I to obtain the average shrinkage rate of the GMT sheet and needled PET fabric composite two-layer structure of 0.354%.
The formula I is as follows: t is 70.9521+0.2318d-0.281T
t-preheating for min;
d-sheet thickness, mm;
t-hot air temperature, DEG C.
The process numerical simulation in the second step specifically comprises the following steps:
step 2.1, carrying out meshing division, heat transfer model setting, contact and friction setting, hourglass control, energy dissipation control and time step control;
and 2.2, inputting the composite material and the parameters of the male die and the female die set in the step one.
And 2.3, acquiring the node force information of the male die and the female die through simulation calculation.
And in the second step, an LS-DYNA finite element program is used for simulation calculation, and specifically:
1. and carrying out grid division.
2. Setting a heat transfer model, wherein the heat transfer model mainly comprises two heat transfer modes of radiation, air cooling heat exchange and contact heat transfer, and the contact heat transfer mode is selected;
defining a compression molding CONTACT mode through keywords CONTACT _ FORMING _ ONE _ WAY \, SURFACCE _ TO _ SURFACCE _ THERMAL, wherein the FORMING _ ONE _ WAY is a CONTACT type specially used for molding, and calculating the CONTACT interface force by using a penalty function algorithm;
since LS-DYNA was originally used for collision analysis, if used for profiling analysis, the default parameter settings must be modified, where the modified penalty function stiffness factor SLSFAC is 0.1;
friction is generated by the contact collision of the die with the sheet during the press molding process, so the friction coefficient needs to be determined, and the friction force is calculated by using a coulomb model, wherein the average friction coefficient is taken as 0.1.
3. Performing hourglass control, wherein the ratio of the hourglass energy to the total energy is less than 10% to ensure that the calculation result is effective; on the other hand, the hourglass control coefficient cannot be too large, which causes unstable calculation when the hourglass control coefficient is greater than 0.15, so the hourglass control setting IHQ is 4 and the hourglass energy coefficient setting QH is 0.1; the ENERGY dissipation CONTROL is set by the keyword CONTROL _ ENERGY, setting HGEN 2, RWEN 2, SLNTEN 2, RYLEN 2.
4. And controlling the time step length, wherein in LS-DYNA software, the convergence of an explicit time integration algorithm is conditional, and the explicit time integration algorithm is stable only when the time step length delta t is less than the critical time step length, and is calculated by using a formula II and a formula III:
the formula II is as follows:
the formula III is as follows:
Δ t — the characteristic length of the cell;
c-the speed of sound of the material;
in the compression molding simulation, when the deformation increases with the advance of time, the delta t can be rapidly reduced, and the integral algorithm is shown to be diverged to cause the simulation to be interrupted. In order to avoid this, a quality scaling technique may be used to set a duration value Δ t by the key word CONTROL TIMESTEPszIn the simulation, if Δ t < t occursszThe process automatically increases the density of the structural material and increases the time step. Here, take Δ tsz0.0000025, setting the time step scaling factor TSSFAC to 0.9 and DTINIT to 0, and setting the initial step by the program; and obtaining a numerical simulation result in the compression molding process through software operation, thereby obtaining the node force information of the mold in the compression molding process.
The grid division specifically uses swept grid division, and the grid is divided by SOLID168 units.
As shown in fig. 4, the composite material adopts shell163 thin shell units, and the sheet grid is a regular quadrilateral unit.
The advantage of this unit is a fast calculation speed.
The simulation calculation used the Belytschko-Tsay algorithm.
The shell163 thin shell cell has 11 different algorithms, here the Belytschko-Tsay algorithm is used, which has the advantage of fast calculation speed.
In the third step, a load mapping method is used for constructing topological optimization boundary conditions of the male-female die structure, specifically:
firstly, determining a material, wherein a sheet material is a PP-based GMT composite material with the glass fiber content of 30%, looking up related data and inputting mechanical property parameters and thermodynamic property parameters of the GMT composite material, the thickness of the sheet material is defined according to the actual thickness of a part, and the material of a punch die and a die is 45# steel;
and then determining technological parameters, setting a male die to fix a lower table top of the hydraulic press, closing the female die under the belt of the press, setting the forming pressure of the die to be 13MPA, setting the closing speed of the upper die after contacting the sheet to be 8mm/s, and setting the initial temperature of the sheet to be 220 ℃. The temperature of the die is 40 ℃, the water temperature of the cooling water channel is 20 ℃, and the pressure maintaining time is 80 s;
and then, obtaining a numerical simulation result through software operation, and obtaining node force information of the die in the compression molding process from the simulation result, so that the node force information is used as a boundary condition for next topological optimization through load mapping.
The fourth step specifically comprises the following steps:
step 4.1, establishing a structural topology optimization model of the punch-die; specifically, the method comprises the following steps:
as shown in fig. 5, firstly, an optimized design region of a punch and a die is determined through analysis of a die structure, then a topological optimization mathematical model corresponding to the punch and the die of the die is constructed, and an optimal material distribution mode of the optimized design region of the punch and the die is obtained through iterative solution of the established mathematical model, so that the purpose of saving most materials and realizing light weight of the die is achieved on the premise of meeting the original rigidity and strength of the die.
The specific method of iterative solution is as follows:
in the optimization process of the male and female dies of the die, the problem of mass minimization can be equivalent to the problem of volume minimization. And analyzing the real working condition of the punch-die and the die, based on a solid isotropic material punishment method (SIMP), according to the compression molding numerical simulation calculation result of the upper section, constructing an SIMP optimization model by taking the maximum displacement of the node of the stress concentration area as a constraint condition, taking the material unit density as a design variable and taking the minimum volume of the structure of the punch-die as an optimization target, wherein the P value is set to be 3.
The specific formula of iterative solution is as follows:
the formula four is as follows:
the formula five is as follows:
and 4.2, topologically optimizing the structure of the male die and the female die.
The step 4.2 specifically comprises the following steps:
step 4.2.1, setting an optimization variable;
step 4.2.2, defining an optimization target and constraint conditions;
and 4.2.3, calculating and obtaining a topology optimization result.
Specifically, according to the analysis of the real working conditions of the die punch and die, the solution is carried out by using OptiStruct based on the SIMP material interpolation optimization model of the die punch and die constructed in the step 4.1. OptiStruct describes the three elements of the optimization design through different types of information cards.
1. Setting an optimization variable;
in the topological optimization of the punch-die, the unit density after optimization is more and more compact 1, which indicates that the more important the material is, the more important the punch-die structure is designed, the more the material is kept; the more toward 0, whether to retain can be determined from the analysis of the convex-concave structure. The design area and the non-design area need to be selected when designing the optimization variables.
2. Defining an optimization target and constraint conditions;
the volume response is selected and an objective function minimization is defined. By means of numerical simulation of the compression molding process of the automobile hat rack main body, node numbers with large stress concentration and deformation of a mold in the compression molding process can be obtained, LS-Presiti post-processing is applied to obtain the serial numbers and displacement numerical values changing along with time, the serial numbers and the displacement numerical values are derived into txt documents, and corresponding node displacement loads in Hyperworks are defined according to the results so as to facilitate subsequent optimization of the mold.
Applying boundary conditions and determining an optimized area, wherein the molded surfaces of the female die and the male die and the position of the cooling water channel are kept unchanged in the optimized design through analyzing the structure of the die, so that a designed area and a non-designed area can be divided, wherein the boundary conditions are the boundary conditions.
3. Trial calculation;
preliminary trial calculation is carried out, if the calculation is passed, the optimal path of load transmission can be found through a topological optimization algorithm and through the continuous iterative calculation process, the optimal solution of topological optimization is obtained, the optimal distribution mode of the convex-concave mould material is obtained, and the calculation results are shown in fig. 6 to 9.
4. Checking topology optimization;
the topological appearance result of the female die and the male die of the die can be obtained through the tape-stacking calculation, the density threshold value is set to be 02, and the topological appearance cloud chart is shown in fig. 10 and 11.
The sixth step specifically comprises the following steps:
step 6.1, exporting a universal model file by using a finite element structure analysis and optimization software program, and importing the universal model file into three-dimensional software;
and 6.2, reversely drawing the die male and female die structure by using three-dimensional software, thereby obtaining the topologically optimized male and female die structure.
The general model file is an IGES general CAD file, the result of the punch-die structure is optimized as shown in fig. 12 and 13, the re-design result of the punch-die structure of the compression molding die of the automobile hat rack main body is obtained, and the weight of the optimally designed punch-die structure is reduced by 15.6% on the premise of meeting the working condition strength and rigidity through CATIA volume measurement.
The working principle of the invention is as follows:
as shown in fig. 14, firstly, a mold is designed according to a mold design task book and a prior art method, numerical simulation of sheet compression molding is performed through an original mold structure finite element network model, after node information of mold strain is obtained, boundary conditions of mold structure analysis are constructed through load mapping, then, structural analysis is performed on the original mold, a mold structure design improvement area is determined, topology optimization is performed on the mold structure, and finally, secondary design is performed on the mold according to an optimization result, so that a final mold structure is obtained.
Claims (10)
1. An optimization method of a compression molding die for an automobile hat rack is applied to a punch-die for optimizing a compression molding process of the hat rack, and is characterized by comprising the following steps:
step two, carrying out process numerical simulation on the compression molding process of the hat rack by using a structural analysis nonlinear finite element program to obtain node force information of the male die and the female die;
thirdly, constructing a topological optimization boundary condition of the male-female die structure by using a load mapping method;
step four, carrying out topological optimization iterative solution on the male and female die structures by using finite element structure analysis and optimization software;
and step five, improving the structure of the punch-die by using three-dimensional software according to the final shape of the topological optimization of the structure of the punch-die.
2. The method for optimizing the compression molding die for the automobile hat rack according to claim 1, wherein before the step two, the method further comprises the following steps:
step one, designing a compression molding punch-die structure.
3. The optimization method of the automobile hat rack compression molding mold according to claim 2, wherein the first step specifically comprises the following steps:
step 1.1, obtaining the average shrinkage rate of the composite structure through experiments and calculation;
and 1.2, compensating and calculating the shrinkage rate of the product during solidification and cooling by adopting an error compensation mode.
4. The method for optimizing the compression molding die for the automobile hat rack according to claim 1, wherein the process numerical simulation in the second step specifically comprises the following steps:
step 2.1, carrying out meshing division, heat transfer model setting, contact and friction setting, hourglass control, energy dissipation control and time step control;
2.2, inputting the composite material and the parameters of the male die and the female die set in the first step;
and 2.3, acquiring the node force information of the male die and the female die through simulation calculation.
5. The optimization method for the compression molding die of the automotive hatrack as claimed in claim 4, wherein the grid division specifically uses swept grid division, and grid division is performed by using SOLID168 units.
6. The optimization method of the automobile hat rack compression molding mold according to claim 4, wherein shell163 thin shell units are adopted as the composite material, and the sheet grids are regular quadrilateral units.
7. The method for optimizing a mold for molding automotive hatracks, according to claim 4, wherein the simulation calculation uses a Belytschko-Tsay algorithm.
8. The optimization method of the automobile hat rack compression molding mold according to claim 1, wherein the step four specifically comprises the following steps:
step 4.1, establishing a structural topology optimization model of the punch-die;
and 4.2, topologically optimizing the structure of the male die and the female die.
9. The method for optimizing the mold for molding the automobile hat rack according to claim 8, wherein the step 4.2 specifically comprises the following steps:
step 4.2.1, setting an optimization variable;
step 4.2.2, defining an optimization target and constraint conditions;
and 4.2.3, calculating and obtaining a topology optimization result.
10. The optimization method of the automobile hat rack compression molding mold according to claim 1, wherein the sixth step specifically comprises the following steps:
step 6.1, exporting a universal model file by using a finite element structure analysis and optimization software program, and importing the universal model file into three-dimensional software;
and 6.2, reversely drawing the die male and female die structure by using three-dimensional software, thereby obtaining the topologically optimized male and female die structure.
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