【作者】 邓超；

【导师】 杨旭静；

【作者基本信息】 湖南大学 ， 机械工程， 2011， 硕士

【摘要】 面对汽车冲压模具竞争激烈的现状,缩短产品的设计周期,提升设计质量,降低模具成本具有非常重要的意义,然而随着模具结构越来越复杂,结构参数不断增多,求解规模不断扩大,传统方法已不能满足产品设计的效率及精度要求。因此,在汽车冲压模具结构设计过程中迫切需要引入实时计算方法,提升复杂结构的分析精度,进而实现结构参数的优化设计。众多学者对实时计算方法进行了研究,寻找计算精度与效率较高的算法,已取得诸多成果,但仍有较多问题值得进一步探索。本文针对金属薄板冲压成形过程中成形力在板料与模具之间传递的关系,提出一种不同网格类型之间的载荷映射计算方法。该方法通过映射单元的精确定位,在板料壳单元与模具实体的单元之间建立了一种对应关系,构建板料单元节点上的成形力与模具网格之间载荷映射的关系模型,从而得到模具表面的精确的载荷分布。将该方法应用于模具结构的优化中,在精确计算模具各部分所受载荷的基础上进行结构优化,得到了满足强度要求的优化结构模型,实现了模具的轻量化。围绕载荷映射法以及在汽车冲压模具中的应用这一主题,本论文主要开展了以下几方面的研究内容:(1)对板料成形力精确求解进行研究。在对冲压成形相关理论阐述的基础上,结合工程实例,研究了不同工艺参数及不同单元尺寸对成形力的影响;(2)基于成形力的求解对模具载荷映射方法进行研究。映射方法研究包括映射方向的选择,节点的精确定位,成形力的插值计算,并对其进行实例分析及其通过实验对比确定方法的正确性。(3)结合载荷映射及板料成形力的求解对模具结构进行优化分析。利用成形力的精确传递计算方法,得到后续模具结构优化分析的边界条件,对模具进行结构优化设计,从而合理改进模具承载母体结构,使得模具母体达到满足刚强度要求又实现轻量化的目的。更多还原

【Abstract】 Because of the fiery competition in automobile stamping die industry, it is important to shorten product design cycle, improve quality and reduce the cost. Furthermore, there are many other challenges, such as more complex die structure, increasing structural parameters, and expanding solving scales. Hence, the traditional methods can not keep up with the requirements of design efficiency and accuracy in some extent. Therefore, it is urgent to introduce the real-time calculation methods which can improve the analysis accuracy of complex structure and obtain the optimal parameters of structural design.With real-time calculation methods, many scholars have developed numerous researches to find high accuracy and efficiency algorithms, but there are still many further explorations. With load mapping method, this paper carries out optimization analysis to die structure. According to the results of optimization analysis, the die structure is improved validly. More details are presented as follows.1. Precise solution of sheet metal forming force is proposed in this paper. With stamping forming theories and engineering practices, various influence factors of forming force are studied.2. The load mapping method is investigated based on the solution of forming force. Some key issues is discussed in this method, such as the choice of mapping direction, the accurate position of nodes, the interpolation of forming force. Additionally, some practical cases and experimental verification are presented.3. The optimization analysis is proposed to die structure based on the load mapping method and solution of sheet metal forming force. The boundary conditions of the die structure optimization analysis can be obtained, through the method of precisely transfer the forming force. Then optimize the design of the die structure to make the die meet the required strength and realize the purpose of lightweight based on the boundary conditions.更多还原