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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(cuò)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(duì)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(huì)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)
2、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)用DYNAFORM軟件對(duì)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(huì)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
3、,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(duì)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(duì)比分析發(fā)現(xiàn)：數(shù)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】Thedevelopmentcycleofanewtypecarmainlyliesonitsautopanels.Itisverydifficulttoo
4、btainhighqualityproductsonlywithempiricalformulaandtraditional“trialanderrormethod”duetothecomplexautopanels,rigidmanufacturerprecisionandsurfacequalityoftheautopanelsandalotoffactorsaffectingitsstampingformingprocess,inaddition,thedevelopmentcycleislonganditscost
5、sisveryhigh.Therefore,theautopanelsstampingformingsimulationtechnologyhasvitalsignificanceincuttingdownautomanufacturingcircle,reducingcost,improvingdesignqualityandenhancingmarketcompetitiveability.Inthispaper,takenamediumtruck’sroofpanelforexample,someresearches
6、instudyingitsqualityproblemsandsolutionsduringtheroofpanel’sformingprocesswasdonebynumericalsimulationandoptimizationtechnology,andthebestformingconditionswhichhasreferencesignificancetotheactualproductionwasselectedout.Basedonthebasaltheoryofsheetmetalforming,sim
7、ulationtechnologyandoptimizationtechnologywasresearchedinthispaper.Firstly,usingnumericalsimulationindrawingformingandtrimmingprocessanditsspring-back,amediumtruck’sroofpanelwastakenintoaccounttoobtainthedeformationcharacteristicsoftheblankandstudythequalityproble
8、msthatmayappearintheformingprocessandtheimpactoftheparameters(gapbetweendieandpunch,frictionmodulus,blankholderforceanddraw-beadresistance);Secondly,thi
