CN112163281A - CAE simulation analysis method for thermal deformation of vehicle body sheet metal part - Google Patents
CAE simulation analysis method for thermal deformation of vehicle body sheet metal part Download PDFInfo
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Abstract
The invention discloses a CAE simulation analysis method for thermal deformation of a vehicle body sheet metal part. According to the method, second analog data obtained by stamping deformation simulation analysis of first analog data of a vehicle body sheet metal part are imported into a welding process vehicle body sheet metal part thermal deformation simulation system, third analog data obtained by welding thermal deformation simulation analysis of the process vehicle body sheet metal part are obtained, and then coating process thermal deformation simulation analysis is carried out on the third analog data to obtain fourth analog data. The method can analyze the thermal deformation only by a 3D digital model of the vehicle body, breaks through the constraint condition that the traditional method must utilize a real vehicle, thereby advancing the time for verifying and taking measures of the thermal deformation problem of the sheet metal of the new vehicle type from a T stage (real vehicle stage) to a CST/P/D stage (drawing stage), and greatly shortening the maturity period of the real vehicle.
Description
Technical Field
The invention belongs to a vehicle part simulation technology, and particularly relates to a vehicle body sheet metal part deformation simulation technology.
Background
The light weight of the automobile body is one of the main methods for improving the oil consumption in the automobile industry. The common method in the industry is to reduce the material thickness of sheet metal parts (particularly the outer covering skin) to the maximum extent by using new materials and optimizing the structural design of the vehicle body on the premise of ensuring the requirements of collision, strength and the like, thereby achieving the effect of reducing the weight of the vehicle body and further reducing the oil consumption of the whole vehicle. However, the sheet metal thickness of the outer cover (door, hood, side panel, ceiling, etc.) is reduced, the deformation resistance thereof is deteriorated, and the problem that the body in white is deformed after baking due to stress concentration and release by heat such as stamping and welding during baking in a paint shop is increasing.
Aiming at the problem of baking deformation of a sheet metal of an outer covering part of a new vehicle type, the main verification method in the prior industry is to use a real vehicle for verification in a T stage (production preparation stage), and grope and search the best countermeasure through continuous trial, verification and comparison effects. The method has the advantages of simple implementation process, visual problem/countermeasure effect and the like, but has the following defects:
(1) the number of actual vehicles in the trial production stage is small, and the process conditions of each workshop in the trial production stage are not solidified, so that a real object deformation result is difficult to obtain, and accidental factor influence is difficult to eliminate;
(2) the metal plate has many factors influenced by thermal deformation, and a method for finding effective countermeasures through a real vehicle is very difficult and often needs multiple rounds of verification; the verification process needs the collaborative cooperation of related departments such as design, stamping, welding, coating and the like, and the organization coordination business volume is large. Therefore, the cost of manpower and material resources consumed in the real vehicle verification process is high, and the quality maturation period is long;
(3) in the trial-manufacturing stage, the material objects such as a stamping die, a welding clamp and the like of the new vehicle model are processed, and at the moment, the molded surface of the covering part is adjusted, so that high die and clamp modification cost is generated, and development cost control of the new vehicle model is not facilitated.
Therefore, the method for verifying the real vehicle to correspond to the problem of metal plate thermal deformation has adverse effects on improving the quality of a new vehicle model, shortening the quality aging period, reducing the development cost and the like.
Disclosure of Invention
The invention aims to provide a CAE simulation analysis method for the thermal deformation of a vehicle body sheet metal part in a whole process flow, which can be used for quickly determining the deformation position and the deformation data of the vehicle body sheet metal part.
The technical scheme of the invention is as follows: second analog data obtained by stamping deformation simulation analysis of first analog data of a vehicle body sheet metal part are imported into a welding process vehicle body sheet metal part thermal deformation simulation system, third analog data obtained by welding process thermal deformation simulation analysis of the vehicle body sheet metal part are conducted, and then coating process thermal deformation simulation analysis is conducted on the third analog data to obtain fourth analog data.
The first digital-analog data of the automobile body sheet metal part are imported into AUTOFORM software (system), the second digital-analog data are imported into Abaqus software (system), and the third digital-analog data are subjected to thermal deformation simulation analysis of the coating process by utilizing the Abaqus software.
The further technical characteristics are that the simulation analysis method for the deformation in the stamping process comprises the following steps: the method comprises the steps of importing first digital-analog data of the automobile body sheet metal part into stamping deformation simulation analysis software of the automobile body sheet metal part, setting a stamping direction, defining material attributes (material type, material thickness and the like) of the first digital-analog data, planning a stamping process, designing a post-process die surface, a drawing pressing surface and a drawing process, setting corresponding tool bodies and analysis precision parameters, and finally carrying out simulation calculation to obtain second digital-analog data containing a stress strain result. The method comprises the steps of importing first digital-analog data of a constructed vehicle body sheet metal part into a stamping deformation simulation system of a process vehicle body sheet metal part, modifying a drawing pressing surface and a drawing process after the first digital-analog data are endowed with a first product attribute, a first material attribute and a first process attribute, confirming an edge trimming and punching expansion angle, setting analysis precision parameters, and carrying out simulation analysis to obtain second digital-analog data containing stress and strain results.
The further technical characteristics are that the simulation analysis method for the thermal deformation in the welding process comprises the following steps: and importing the second modulus data into Aabqus software, endowing the Aabqus software with second material attributes (density, elastic modulus, plastic stress/strain and the like), determining the position relation of the assembly of the sheet metal parts of the automobile body, setting an interactive relation based on the analysis steps of the welding process, setting boundary conditions, performing simulation analysis on deformation of the welding process, and obtaining third modulus data including stress-strain data after the stamping and welding process.
The further technical characteristics are that the coating process thermal deformation simulation analysis method comprises the following steps: and (3) introducing the stress-strain data in the third digital-analog data into Aabqus software as Part, endowing the third digital-analog data with third material attributes (heat conduction coefficient, thermal expansion coefficient, specific heat capacity and the like), determining the position relation of the assembly of the sheet metal Part of the vehicle body, establishing an analysis step based on a coating process, setting an interactive relation and boundary conditions, performing simulation analysis on the deformation of the coating process, and obtaining fourth digital-analog data containing the stress-strain result after the processes of stamping, welding and coating.
The method is further technically characterized in that in the welding simulation analysis method, based on an Abaqus system, simulation Step analysis of each Step is set according to the actual welding sequence of each part, the number of welding points and the welding time of each point; selecting the type of Step as Coupled temp _ displacement; the Response type is selected as transition, the welding Time of each welding point is input in the Time period, and the connection sequence between steps is consistent with the welding sequence of a real object.
The method is further technically characterized in that in the coating process thermal deformation simulation analysis, the set boundary conditions comprise the vehicle body sheet metal part gravity and the coating jig constraint setting.
The theoretical principle of the invention is as follows:
in the stress/strain analysis model, the displacement (deformation amount) is an unknown amount, and the temperature of each node is taken as a known external load, thereby calculating the thermal strain:th＝α(θ-θI)
for statics analysis calculation, strainmech＝-th
Stress solution sigma D (theta)mech
Wherein, the alpha-thermal expansion coefficient,
theta-the current temperature of the molten steel,
θI-the initial temperature of the liquid at which the liquid is at least partially evaporated,
according to the above equation, the temperature field affects the mechanical field by thermal expansion (contraction) affecting the mechanical properties associated with temperature, resulting in stress and displacement.
By using the method, the thermal deformation analysis can be carried out only by using a 3D digital model of the vehicle body, the constraint condition that the traditional analysis verification method must utilize a real vehicle is broken, so that the analysis and countermeasure time of the sheet metal thermal deformation problem of the new vehicle type can be advanced from the T stage (real vehicle stage) to the CST/P/D stage (drawing stage), and the maturity period of the real vehicle is greatly shortened.
Meanwhile, by using the CAE simulation analysis method, the improvement effects (such as changing the digital-analog model of the sheet metal part, adding a reinforcing paste and the like) under different countermeasure conditions can be quickly obtained, so that the optimal countermeasure scheme can be quickly found, the deformation problem is found and eliminated in the design stage, the appearance quality of a new vehicle type is improved, multiple adjustments of a mold, a clamp and the like in the material object stage are effectively avoided, and the high modification cost is reduced.
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FIG. 1 is a flow chart of the present invention.
Detailed Description
The following detailed description is provided for the purpose of explaining the claimed embodiments of the present invention so that those skilled in the art can understand the claims. The scope of the invention is not limited to the following specific implementation configurations. It is intended that the scope of the invention be determined by those skilled in the art from the following detailed description, which includes claims that are directed to this invention.
As shown in fig. 1, one of the embodiments of the present invention is as follows:
1. the deformation simulation analysis of the stamping process comprises the following steps:
firstly, introducing a product: importing first digital-analog data of the constructed vehicle body sheet metal part, such as a CATPArt format or an IGS format product digital-analog, into AUTOFORM software, if the data is missing, repairing, and endowing product attributes including defining product types and symmetrical types in the AUTOFORM software;
(ii) attribute the material, including defining the material: locally importing material parameters corresponding to the 2D graph of the part, and setting the thickness of the material;
endowing process attributes, including setting the stamping material direction: setting a stamping center and a rotation angle;
procedure planning: according to the stamping process of a product, the working procedures of drawing, flanging, trimming and the like are set, the simulation command type of each working procedure is selected according to the actual processing condition, and corresponding parameters are set;
fourthly, designing a post-process die surface: designing the process die surfaces of all the procedures step by step from the last procedure according to the procedures planned and set by the procedures;
drawing and pressing surface design/drawing process supplement design: modifying the product by modification, wherein the modification comprises filling holes on the surface of the product, sewing up the boundary, setting over-drawing and the like; for the part with unsmooth transition connection, the smooth connection can be carried out through the adjustment of a control line or by using 'Fill';
sixthly, trimming inspection: performing trimming and punching expansion angle confirmation on the Trimchk page;
the BL material design: editing BL shi sample and size;
tool body/precision setting: according to the working procedures set by the working procedure planning, the working procedure tool bodies are set from the first working procedure step by step backwards, and the analysis precision parameters are set, so that the accuracy of the analysis result is ensured;
ninthly, simulation analysis is carried out: and after the steps are completed, the simulation modeling of the stamping process is completed, and the stress-strain condition of the part generated in the stamping process is obtained after the simulation modeling is submitted and analyzed, so that second digital-analog data containing stress and strain data is obtained.
2. The simulation analysis of the welding thermal deformation comprises the following steps:
firstly, introducing a result: importing the analysis result of the stamping process as an input condition; importing the second modulus data into Abaqus software, and selecting an 'explicit' analysis type of the software to perform subsequent steps;
(ii) attribute the material, including defining the material: under the 'Property' interface of software, firstly selecting an 'Edit Material' name, sequentially selecting Material properties such as Density, Elastic (Elastic modulus), Plastic (Plastic stress/strain), Conductivity (thermal Conductivity), Expansion (thermal Expansion coefficient), Specific heat, viscosity change curve of Expansion glue/edge folding glue and the like, and inputting real values of each Material; secondly, creating a Section, sequentially selecting a type of the Section from Shell → Homogeneous, and setting the material thickness of the Section; finally, each Section is endowed to a corresponding part;
assembling parts/inspection: assembling all the components, and checking and adjusting the position relation of the components to make the components consistent with the actual conditions;
setting an analysis step: the simulated "Step" for each Step is set (analyzed) based on the actual welding sequence of the parts, the number of weld points, and the welding time for each point. The type of the Step is selected as ' Coupled temp _ displacement ', the type of the Response ' is selected as ' Transient ', the welding Time of each welding spot is input in ' Time period ', and the connection sequence between the steps must be consistent with the welding sequence of the real object;
setting an interaction relation: setting a Creat constraint and a type selection Tie under an Interaction interface; the Interaction relation among the components is set in turn according to the material thickness (rigidity) of the components and the size of the grids;
setting boundary conditions (load): on the 'Load' interface, firstly, sequentially creating Load 'Create Load' for each 'Step', selecting 'Thermal' and 'Type' of each 'Load', inputting heat (Thermal Load) of each welding point and storing; secondly, under a Load interface, setting a constraint ConDition ' Creat Boundry Condition of the part in each ' Step ' state according to the fixing ConDition of a clamp to the part during welding (the Type selection of ' Thermal ' and ' Type ' of each boundary ConDition must be consistent with the requirement and be accurate); finally, a Predefined temperature Field "Creat Predefined Field" of the component is set under the "Load" interface, the corresponding "Thermal" and "Type" types are selected, and the initial temperature and other parameters of the component are input.
Submitting analysis: after all the parameters and the steps are set, modeling of a welding processing process (welding high temperature, clamping by a clamp and the like) is completed, a specific thermal analysis module and type in the Abaqus are selected, and the change condition of stress and strain in the part under the influence of external factors such as welding, clamping by the clamp and the like is analyzed;
and (b) carrying out aftertreatment: and after the analysis is finished, obtaining third digital-analog data containing the stress-strain data of the part after the stamping and welding process.
3. The coating process thermal deformation simulation analysis comprises the following steps:
firstly, introducing a result: importing stress and strain data (ODB file) in the third digital-to-analog data as Part in Abaqus software;
(ii) attribute the material, including defining the material: under the software 'Property' interface, selecting the 'Edit Material' name, sequentially selecting the sub-options of Density, Elastic (Elastic modulus), Plastic (Plastic stress/strain), Conductivity (thermal Conductivity), Expansion (thermal Expansion coefficient), Specific heat and the like, and inputting the real value of each Material; secondly, creating a Section, sequentially selecting a type of the Section from Shell → Homogeneous, and setting the material thickness of the Section; finally, each type of "Section" is assigned to a corresponding part (the setting of "Shell Offset" in "Edit Section Assignment" needs to be consistent with the requirement);
assembling parts/inspection: checking and confirming the position relation of each component again;
setting an analysis step: creating a Step, namely, in the Step creating process, options such as a Procedure Type, a Response, an Automatic Stabilization, an inclusion and the like need to be selected and set corresponding settings according to requirements;
setting an interaction relation: setting a Creat constraint and a type selection Tie under an Interaction interface; the Interaction relation among the components is set in turn according to the material thickness (rigidity) of the components and the size of the grids;
setting boundary conditions (load): different boundary conditions or loads are set respectively according to different analyzed components (for example, when the engine hood is analyzed, the boundary conditions of gravity load and baking temperature need to be set, and when the side wall is analyzed, only the boundary conditions of baking temperature need to be set). The setting method of the baking temperature comprises the following steps: selecting corresponding Types of 'Category' and 'Types for Selected Step' from 'Step 1', entering a temperature setting interface, converting the painting and baking temperature-time curve data of the part by a specific method, and inputting the converted curve data ('Creat Amplitude') and the highest temperature value after selecting the curve type on the temperature setting interface;
the simulation parameters of the two factors are needed to be set corresponding to the parts (such as the engine cover) with larger influence of gravity and the coating jig on deformation.
The gravity setting method comprises the following steps: selecting Create Load on a Load interface, selecting and setting subsequent sub-options, and inputting corresponding parameter values and the direction of selecting good force;
the simulation method of the supporting effect of the jig comprises the following steps: selecting a Create boundary condition on a Load interface, and setting the constraint condition of the component in each direction according to information such as a supporting (limiting) form, a position, a contact surface area and the like of the component by a jig;
submitting analysis: after corresponding material characteristic parameters, loads and boundary conditions are set, modeling of a coating processing process is completed, a specific thermal analysis module and type in the Abaqus are selected, and the change condition of stress and strain in parts under the influence of external factors such as coating baking, jig supporting (limiting) and the like is analyzed;
and (b) carrying out aftertreatment: and after the analysis is finished, obtaining the stress and strain data after the combined action of the punching, welding and coating processes. The corresponding display content of the software is selected, so that the deformation conditions (the direction of the deformation trend and the deformation quantity numerical value) of all parts of the part processed by the process can be visually seen through colors.
The invention creatively establishes the CAE simulation analysis method for the thermal deformation of the automobile sheet metal part based on the auto form and the Abaqus, can realize the simulation analysis of the whole process of stamping, welding and coating, and fills the blank of the simulation analysis technology aiming at the pain point problem in the industry at present.
The analysis process and the analysis method are continuously debugged, corrected and perfected through simulation analysis of a plurality of vehicle types and a plurality of parts and comparison verification with a real object. The simulation modeling of each process is carried out according to the method specified in the system, the matching degree of the final analysis result and the real object reaches 81 percent (the difference between the simulation analysis and the actual measurement value is within +/-1 mm), and the simulation modeling method has the condition of being applied in the drawing stage of the new vehicle model.
After the analysis is finished, aiming at the position where the deformation exceeds the reference, the CAE analysis is carried out on different countermeasures by modifying the product digifax (such as changing the shape) or adjusting the process conditions (such as increasing the number of tool fixtures) to find out an effective countermeasure; and determining the optimal corresponding scheme by comparing the multiple effective schemes.
The invention has been carried out on a plurality of car body sheet metal parts such as engine covers, tail doors, side wall outer plates, ceiling outer plates and the like of a plurality of car types for equal analysis and verification, and the effects after implementation on new car types are as follows:
(1) quality aspect: the gap section difference level of the vehicle cover object of the new vehicle type is obviously improved (the warping deformation is reduced to be within a standard range), and the appearance quality is improved (the concave-convex deformation of the appearance surface is eliminated);
(2) in the aspect of cost: the requirement of a thermal deformation verification vehicle is remarkably reduced, the average modification times of a die/check tool of each new vehicle model is reduced by 2-3 times, and the cost of die repair and the like is reduced by about 120 thousands yuan;
(3) the aspect of the product cooking cycle is as follows: the maturity period of the new vehicle type is averagely shortened by 3-4 months, and the guarantee capability of the mass production schedule is continuously improved.
Claims (6)
1. A CAE simulation analysis method for thermal deformation of a vehicle body metal plate part is characterized in that second analog data obtained by stamping deformation simulation analysis of first analog data of the vehicle body metal plate part are led into a welding process vehicle body metal plate part thermal deformation simulation system, third analog data obtained by welding process thermal deformation simulation analysis of the vehicle body metal plate part are conducted, and then coating process thermal deformation simulation analysis is conducted on the third analog data to obtain fourth analog data.
2. The CAE simulation analysis method for the thermal deformation of the sheet metal part of the vehicle body according to claim 1, wherein the simulation analysis method for the deformation in the stamping process comprises the following steps: the method comprises the steps of importing first digital-analog data of the automobile body sheet metal part into stamping deformation simulation analysis software of the automobile body sheet metal part, setting a stamping direction, defining material attributes of the first digital-analog data, planning a stamping process, designing a die surface, a drawing pressing surface and a drawing process of a later process, setting corresponding tool bodies and analysis precision parameters, and performing simulation calculation to obtain second digital-analog data containing a stress strain result.
3. The CAE simulation analysis method for the thermal deformation of the sheet metal part of the vehicle body according to claim 1, wherein the simulation analysis method for the welding thermal deformation comprises the following steps: and giving a second material attribute to the second analog data, determining the position relation of the assembly of the sheet metal parts of the vehicle body, setting an analysis step based on the welding process, setting an interaction relation, setting boundary conditions, and carrying out simulation analysis on the welding process to obtain third analog data containing stress and strain data after stamping and welding.
4. The CAE simulation analysis method for the thermal deformation of the sheet metal Part of the vehicle body according to claim 1, wherein the CAE simulation analysis method for the thermal deformation of the coating process comprises the steps of importing stress-strain data in third digital-analog data as Part, endowing the third digital-analog data with third material attributes, determining the position relation of the assembly of the sheet metal Part of the vehicle body, setting an interactive relation based on the analysis step of the coating process, setting boundary conditions, performing simulation analysis on the coating process, and obtaining fourth digital-analog data containing the stress-strain data after the stamping, welding and coating processes.
5. The CAE simulation analysis method for the thermal deformation of the sheet metal part of the vehicle body according to claim 3, wherein the setting and analyzing step comprises the following steps: setting simulated Step analysis of each Step according to the actual welding sequence of each part, the number of welding points and the welding time of each point based on an Abaqus system; selecting the type of Step as Coupled temp _ displacement; the Response type is selected as transition, the welding Time of each welding point is input in the Time period, and the connection sequence between steps is consistent with the welding sequence of a real object.
6. The CAE simulation analysis method for the thermal deformation of the vehicle body sheet metal part as claimed in claim 4, wherein the set boundary conditions comprise the gravity of the vehicle body sheet metal part and the constraint setting of a coating jig.
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Cited By (3)
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| CN112719124A (en) * | 2021-01-27 | 2021-04-30 | 东风汽车集团股份有限公司 | Stamping synchronous engineering method, system and medium for improving appearance quality of body-in-white |
| CN113515404A (en) * | 2021-07-01 | 2021-10-19 | 中国汽车技术研究中心有限公司 | Electronic sample car data checking method based on CATIA and related equipment |
| CN113656909A (en) * | 2021-08-05 | 2021-11-16 | 大明重工有限公司 | Bending simulation and mold evaluation method |
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