产品跌落冲击动力学分析与耐撞性能稳健设计
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摘要
跌落冲击是许多小型机电产品在其寿命周期内失效的常见原因。目前,小型机电产品设计开发一般遵循初步设计、样机跌落试验、再改进设计的传统模式。为确保产品的耐撞性能,产品批量生产前须按相关标准通过跌落试验的检验。然而,即使在产品开发中通过了样机跌落试验检验,产品在使用过程中跌落损坏仍是这类产品失效的主要原因之一,而且传统的产品耐撞性设计模式费钱费时,已越来越不适应于小机电、特别是数字产品个性化、多样化和快速响应的市场要求。因此,如何突破传统的产品跌落冲击耐撞性设计模式、提高产品的耐撞性与稳健性就成为亟待研究的课题。
本文从产品跌落冲击动态响应、跌落冲击耐撞性能分析、结构参数优化以及耐撞性能稳健设计优化几个方面进行了理论分析与试验研究。主要研究工作如下:
针对小型产品跌落冲击耐撞性能设计的特殊性以及产品跌落冲击耐撞性动态设计中存在的不确定性,在总结了产品跌落冲击动态响应以及稳健设计的研究进展基础上,提出了基于数值模拟耐撞性综合评价体系的产品跌落冲击耐撞性能稳健设计优化方法。并以目前常用便携式电子产品---移动硬盘和存在液固耦合作用的弹性储液容器为研究对象,借助数值模拟技术,进行了移动硬盘和弹性储液容器的跌落冲击动力学特性分析和耐撞性能稳健优化设计。
建立了移动硬盘关键部件---磁头传动臂组件有限元模型,通过理论分析、有限元模态分析和模态试验,获得了磁头传动臂组件的模态参数。进行了不同冲击波形、不同脉冲幅值、不同脉冲宽度载荷下的磁头传动臂组件动态响应分析,获得典型冲击载荷下的磁头传动臂组件冲击响应谱。基于移动硬盘各零部件相互装配关系,采用对称罚函数接触算法建立了移动硬盘整体跌落有限元模型,通过移动硬盘跌落冲击实验验证了有限元模型的可行性,提出了基于虚拟跌落试验的综合产品外在形貌和内在功能的耐撞性能评价指标,探讨了传动臂材料、传动臂形状以及跌落角度对移动硬盘耐撞性能的影响,为移动硬盘耐撞性能优化设计提供了理论依据。
基于移动硬盘整体跌落有限元模型,采用有限元分析与试验设计相结合方法,建立了移动硬盘关键零件的结构参数与跌落冲击响应之间的非线性映射关系,兼顾不同的优化目标函数,发展了神经网络与遗传算法相结合的移动硬盘耐撞性能多目标优化算法,通过结构参数优化提高了移动硬盘的耐撞性能。针对移动硬盘跌落冲击条件的多样性和随机性,引入稳健设计理论,应用田口方法分析了移动硬盘耐撞性能设计中的可控因素和噪声因素,并对减小地面硬度噪声的影响进行了稳健设计,获得了关键零件结构参数的最佳匹配,提高了移动硬盘耐撞性能的稳健性。
针对生活中广泛运用的弹性储液容器的跌落冲击特性,考虑跌落冲击存在的不确定性和液固耦合作用,采用ALE算法建立了弹性储液容器的跌落冲击液固耦合动力学有限元模型。探讨了不同冲击参数、结构参数对饮水桶桶体等效应力分布的影响,采用有限元和人工神经网络相结合方法来计算储液容器跌落冲击接触点最大应力值,避免了探求储液容器跌落冲击下数学模型建立的复杂过程,为储液容器耐撞性评价与优化设计提供理论支撑。
本文通过提出产品跌落冲击耐撞性能稳健设计优化方法,对移动硬盘和弹性储液容器的跌落冲击动态响应进行了定量分析和稳健优化设计,提高了产品跌落冲击耐撞性能,验证了所提产品跌落冲击耐撞性能稳健设计优化方法的正确性和有效性,为产品跌落冲击动力学分析和耐撞性能稳健设计提供了新的理论依据和实践参考。
Drop-impact lead to failure for various types of small electronic motors in useful life period. At present, design cycles for manufactured produce is preliminary design, sample impact experiments and re-design. The final product has to use standard experiments to check the drop-impact on prototype product to achieve the tough crashworthiness. However, the product still will suffer drop impact failure, even though the sample drop impact passed. During manufacture processing, the drop-impact is a major product failure reason. Furthermore, the traditions design model is time-consuming and highly-cost so that it is not well-suitable for small type manufactured produce. Shortening the design cycle of drop impact and providing crashworthiness robust design for manufactured produce are urgently needed.
The main work of this thesis can be summarized as follows:
Considering particularity and uncertainty of drop impact crashworthiness design, literature review from the research about the dynamic response of drop impact and impact crashworthiness robust design has been done. Drop impact crashworthiness robust design optimize frame is presented and developed based on crashworthiness evaluation for virtual drop test. This work enrichs design theory and method for dynamic design. In this thesis, precision electronic products mobile hard disk and liquid-sold coupled fluid-filled container are chosen as two samples to investigate the capability of dynamic drop-impact, crashworthiness design, optimism structural parameters, and crashworthiness robust design.
A 2.5 inch mobile hard disk finite element modal is modeled according to key components function of head actuator arm assembly. Parameters of modal are achieved by means of theoretical analyse, finite element modal analyse and experiment. The response spectrum of typical impact is generated using dynamic response analysis on various types of pulse waveform, pulse amplitude and pulse width. Based on the function of hard disk assembly, a finite element model of mobile hard disk has been built using penalty method and is validated using sample drop test. Crashworthiness evaluate is set forward based on outer appearance and inner function. Crashworthiness of head actuator arm material, shape and drop angle are studied, which can be taken as practical references for mobile hard disk crashworthiness optimal design.
Non-linear mapping relation of key components structure parameters and drop impact response is built using FEM (finite element method) and experimental design. Multiple objective optimization algorithm with crashworthiness is analyzed based on ANN(Artificial Neutral Network)and GA(Genetic Algorithm). Considering drop impact diversity and randomicity, crashworthiness robust design aim at reducing influence of floor rigidity is researched through analyzing controlled variable parameters and noise factor. Key components optimal structure parameters are acquired through taguchi method.
Considering drop impact uncertainty and liquid-sold coupled of elasticity fluid-filled container, the finite element analysis and Arbitrary Lagrange-Euler (ALE) algorithm are used here, to analyze the influence of drop parameter and drop impact parameters. Mapping relations of fluid-filled container structure parameter, drop impact parameter and contact point stress are set up based on the FEM and ANN. In theoretically, the results are proven to be fundamental method of crashworthiness analysis, evaluation and design for fluid-filled containers. The method avoids complexity process with building drop impact mathematics model.
A drop impact crashworthiness robust design optimize method for manufactured products is developed, which provides us not only a qualitative description but also a quantized description about mobile hard disk and fluid-filled container drop impact in order to enhancing crashworthiness. This research work provides scientific guidance and practical references through a serial of method of parameters selection, experiment design, FEM modeling, dynamic analysis, crashworthiness evaluation, numerical modeling, multiple objective optimization, and robust design.
本文从产品跌落冲击动态响应、跌落冲击耐撞性能分析、结构参数优化以及耐撞性能稳健设计优化几个方面进行了理论分析与试验研究。主要研究工作如下:
针对小型产品跌落冲击耐撞性能设计的特殊性以及产品跌落冲击耐撞性动态设计中存在的不确定性,在总结了产品跌落冲击动态响应以及稳健设计的研究进展基础上,提出了基于数值模拟耐撞性综合评价体系的产品跌落冲击耐撞性能稳健设计优化方法。并以目前常用便携式电子产品---移动硬盘和存在液固耦合作用的弹性储液容器为研究对象,借助数值模拟技术,进行了移动硬盘和弹性储液容器的跌落冲击动力学特性分析和耐撞性能稳健优化设计。
建立了移动硬盘关键部件---磁头传动臂组件有限元模型,通过理论分析、有限元模态分析和模态试验,获得了磁头传动臂组件的模态参数。进行了不同冲击波形、不同脉冲幅值、不同脉冲宽度载荷下的磁头传动臂组件动态响应分析,获得典型冲击载荷下的磁头传动臂组件冲击响应谱。基于移动硬盘各零部件相互装配关系,采用对称罚函数接触算法建立了移动硬盘整体跌落有限元模型,通过移动硬盘跌落冲击实验验证了有限元模型的可行性,提出了基于虚拟跌落试验的综合产品外在形貌和内在功能的耐撞性能评价指标,探讨了传动臂材料、传动臂形状以及跌落角度对移动硬盘耐撞性能的影响,为移动硬盘耐撞性能优化设计提供了理论依据。
基于移动硬盘整体跌落有限元模型,采用有限元分析与试验设计相结合方法,建立了移动硬盘关键零件的结构参数与跌落冲击响应之间的非线性映射关系,兼顾不同的优化目标函数,发展了神经网络与遗传算法相结合的移动硬盘耐撞性能多目标优化算法,通过结构参数优化提高了移动硬盘的耐撞性能。针对移动硬盘跌落冲击条件的多样性和随机性,引入稳健设计理论,应用田口方法分析了移动硬盘耐撞性能设计中的可控因素和噪声因素,并对减小地面硬度噪声的影响进行了稳健设计,获得了关键零件结构参数的最佳匹配,提高了移动硬盘耐撞性能的稳健性。
针对生活中广泛运用的弹性储液容器的跌落冲击特性,考虑跌落冲击存在的不确定性和液固耦合作用,采用ALE算法建立了弹性储液容器的跌落冲击液固耦合动力学有限元模型。探讨了不同冲击参数、结构参数对饮水桶桶体等效应力分布的影响,采用有限元和人工神经网络相结合方法来计算储液容器跌落冲击接触点最大应力值,避免了探求储液容器跌落冲击下数学模型建立的复杂过程,为储液容器耐撞性评价与优化设计提供理论支撑。
本文通过提出产品跌落冲击耐撞性能稳健设计优化方法,对移动硬盘和弹性储液容器的跌落冲击动态响应进行了定量分析和稳健优化设计,提高了产品跌落冲击耐撞性能,验证了所提产品跌落冲击耐撞性能稳健设计优化方法的正确性和有效性,为产品跌落冲击动力学分析和耐撞性能稳健设计提供了新的理论依据和实践参考。
Drop-impact lead to failure for various types of small electronic motors in useful life period. At present, design cycles for manufactured produce is preliminary design, sample impact experiments and re-design. The final product has to use standard experiments to check the drop-impact on prototype product to achieve the tough crashworthiness. However, the product still will suffer drop impact failure, even though the sample drop impact passed. During manufacture processing, the drop-impact is a major product failure reason. Furthermore, the traditions design model is time-consuming and highly-cost so that it is not well-suitable for small type manufactured produce. Shortening the design cycle of drop impact and providing crashworthiness robust design for manufactured produce are urgently needed.
The main work of this thesis can be summarized as follows:
Considering particularity and uncertainty of drop impact crashworthiness design, literature review from the research about the dynamic response of drop impact and impact crashworthiness robust design has been done. Drop impact crashworthiness robust design optimize frame is presented and developed based on crashworthiness evaluation for virtual drop test. This work enrichs design theory and method for dynamic design. In this thesis, precision electronic products mobile hard disk and liquid-sold coupled fluid-filled container are chosen as two samples to investigate the capability of dynamic drop-impact, crashworthiness design, optimism structural parameters, and crashworthiness robust design.
A 2.5 inch mobile hard disk finite element modal is modeled according to key components function of head actuator arm assembly. Parameters of modal are achieved by means of theoretical analyse, finite element modal analyse and experiment. The response spectrum of typical impact is generated using dynamic response analysis on various types of pulse waveform, pulse amplitude and pulse width. Based on the function of hard disk assembly, a finite element model of mobile hard disk has been built using penalty method and is validated using sample drop test. Crashworthiness evaluate is set forward based on outer appearance and inner function. Crashworthiness of head actuator arm material, shape and drop angle are studied, which can be taken as practical references for mobile hard disk crashworthiness optimal design.
Non-linear mapping relation of key components structure parameters and drop impact response is built using FEM (finite element method) and experimental design. Multiple objective optimization algorithm with crashworthiness is analyzed based on ANN(Artificial Neutral Network)and GA(Genetic Algorithm). Considering drop impact diversity and randomicity, crashworthiness robust design aim at reducing influence of floor rigidity is researched through analyzing controlled variable parameters and noise factor. Key components optimal structure parameters are acquired through taguchi method.
Considering drop impact uncertainty and liquid-sold coupled of elasticity fluid-filled container, the finite element analysis and Arbitrary Lagrange-Euler (ALE) algorithm are used here, to analyze the influence of drop parameter and drop impact parameters. Mapping relations of fluid-filled container structure parameter, drop impact parameter and contact point stress are set up based on the FEM and ANN. In theoretically, the results are proven to be fundamental method of crashworthiness analysis, evaluation and design for fluid-filled containers. The method avoids complexity process with building drop impact mathematics model.
A drop impact crashworthiness robust design optimize method for manufactured products is developed, which provides us not only a qualitative description but also a quantized description about mobile hard disk and fluid-filled container drop impact in order to enhancing crashworthiness. This research work provides scientific guidance and practical references through a serial of method of parameters selection, experiment design, FEM modeling, dynamic analysis, crashworthiness evaluation, numerical modeling, multiple objective optimization, and robust design.
引文
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