FASTAMP前后置处理系统中相关算法的研究
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摘要
板料冲压成形工艺具有生产效率高、产品性能好、加工材料省的特点,广泛应
用于汽车、航天、造船、家电等工业领域。特别是在汽车制造工业中,汽车的大部
分零件都是冲压制造的。在汽车整车产品中,外覆盖件具有市场生命周期短,产品
形状变化频繁、形状复杂、结构尺寸大、成形质量要求高等特点,成为整车产品开
发中的一个关键环节。
传统的覆盖件产品和模具设计主要靠经验和试模来完成,在产品设计阶段,难
以对产品的成形工艺和质量进行有效的评估,因此急需一种有效的分析方法来指导
产品设计。有限元逆算法可以较好地对产品进行数值模拟,在产品设计阶段可以快
速地分析和评估产品的后续加工工艺性,缩短了产品开发周期,降低了生产成本,
可以作为一种新车型覆盖件开发的有效分析工具。
结合华中科技大学模具国家重点实验室开发的基于有限元逆算法的FASTAMP
软件,对软件系统的前、后处理系统中的相关算法问题进行了研究,开发了FASTAMP
软件后处理系统。
在前处理系统中,对网格的质量进行了检查。将网格的边按照空间位置定向排
序搜索,提出了一种快速建立单元关联关系的算法。并在建立了单元关联关系的基
础上,对重复单元、多单元共边等单元缺陷进行了分步检查和修复。同时根据模拟
计算的要求,实现了单元法向量的自动翻转和单元负角的动态检查。
在后处理系统中,对有限元分析中物理量的分布显示算法进行了研究,实现了
单元块、等值线和截面线三种物理量分布显示算法。采用动态划分物理量分布区域
的方法,提出了一种高效快速的等值线显示算法。同时根据后处理系统中的要求,
提出一种截面物理量显示算法,方便观察物理量沿某一方向的分布情况,并比较了
三种显示方法的优缺点。
从理论和实验两个方面对成形极限图(FLD)的建立进行了研究。对传统的FLD
进行了扩展,引入了起皱极限图(WLD),使新的FLD不仅可以反映减薄和破裂的趋
势,还可以比较准确地预测冲压件的起皱趋势。同时又引入了成形不足区,反映板
料变形不足,可能引起冲压件刚性不足、鼓动或产生表面微波纹现象,更加方便地
对于汽车外覆盖件进行成形性分析。
通过大量的系统测试和实际工业应用,验证了所开发的后处理系统的稳定性和
实用性,基本满足有限元模拟后处理的需要。
Sheet metal stamping process is widely used in automobile, aircraft, shipbuilding,
household appliance and other industries with high production efficiency, good product
performance and work material saving. Especially, in the automobile manufacture
industry, most pieces of an automobile are made with stamping process. The cover piece
product is the key link in the automobile product development, which is endowed with the
vivid characters of short market life cycle, large physical dimension, form changing
frequently, high forming quality requirements.
At the product design stage, it is hard to evaluate forming process and quality of the
product effectively. Traditionally, both cover piece product finished and die designed
mostly depend on experience and die setting. So, it is urgent necessary to have a kind of
operative analysis method to instruct product design. The finite element inverse approach
can simulate numerically product forming well and become gradually a useful analysis
method at the cover piece development stage of a new automobile. It is very useful that
the approach can analyze and evaluate the product subsequent process usability, shorten
product development cycle, reduce the manufacturing cost at the stage.
Related algorithm problems are studied in the pre and post process subsystem of the
finite element simulation system, FASTAMP, which is based on inverse approach and
developed by State Key Laboratory of Plastic Forming Simulation and Die & Mould
Technology, HUST. And the post process system of FASTAMP is developed.
In the pre process system, the quality of element meshed is checked. A new searching
algorithm is proposed which can build the element topological connection relationship
quickly. Based on the relationship, the element deficiencies such as duplicate element, and
an element edge shared by many elements are checked and recovered. According to the
requirement of the calculation, the functions that can reverse the element normal direction
automatically and check element negative angle dynamically, are completed.
In the post system, the physical quantity distribution displaying algorithms of finite
element analysis are studied, and three algorithms of element mode, contour mode and
section mode are achieved. A new contour algorithm based on dynamically partitioning
physical quantity distribution zone, is proposed, which can execute quickly and efficiently.
According to the requirement of the post system, a displaying algorithm about physical
quantity distribution in a section is proposed. And then the merits and demerits of the
three modes are compared.
II
The foundation of Forming Limit Diagram(FLD) is studied from two aspect of
theory and experiment. The Wrinkle Limit Diagram is introduced to extend the
conventional FLD. Then the new FLD can reflect not only the tendency of the reducing in
thickness and the fracture but also the tendency of the wrinkling up relatively right. At the
meantime, the insufficient forming area is introduced to reflect the phenomenon of the
insufficient rigidity of stamped product, bulging, micro ripple, which are caused by the
insufficient forming. So the final FLD can analyze the forming of an automobile cover
piece easily.
Through the many system test and practical industrial application, the stability and
practicability of the post process subsystem is demonstrated. And the functions of the
system meet the need of the finite element analysis.
用于汽车、航天、造船、家电等工业领域。特别是在汽车制造工业中,汽车的大部
分零件都是冲压制造的。在汽车整车产品中,外覆盖件具有市场生命周期短,产品
形状变化频繁、形状复杂、结构尺寸大、成形质量要求高等特点,成为整车产品开
发中的一个关键环节。
传统的覆盖件产品和模具设计主要靠经验和试模来完成,在产品设计阶段,难
以对产品的成形工艺和质量进行有效的评估,因此急需一种有效的分析方法来指导
产品设计。有限元逆算法可以较好地对产品进行数值模拟,在产品设计阶段可以快
速地分析和评估产品的后续加工工艺性,缩短了产品开发周期,降低了生产成本,
可以作为一种新车型覆盖件开发的有效分析工具。
结合华中科技大学模具国家重点实验室开发的基于有限元逆算法的FASTAMP
软件,对软件系统的前、后处理系统中的相关算法问题进行了研究,开发了FASTAMP
软件后处理系统。
在前处理系统中,对网格的质量进行了检查。将网格的边按照空间位置定向排
序搜索,提出了一种快速建立单元关联关系的算法。并在建立了单元关联关系的基
础上,对重复单元、多单元共边等单元缺陷进行了分步检查和修复。同时根据模拟
计算的要求,实现了单元法向量的自动翻转和单元负角的动态检查。
在后处理系统中,对有限元分析中物理量的分布显示算法进行了研究,实现了
单元块、等值线和截面线三种物理量分布显示算法。采用动态划分物理量分布区域
的方法,提出了一种高效快速的等值线显示算法。同时根据后处理系统中的要求,
提出一种截面物理量显示算法,方便观察物理量沿某一方向的分布情况,并比较了
三种显示方法的优缺点。
从理论和实验两个方面对成形极限图(FLD)的建立进行了研究。对传统的FLD
进行了扩展,引入了起皱极限图(WLD),使新的FLD不仅可以反映减薄和破裂的趋
势,还可以比较准确地预测冲压件的起皱趋势。同时又引入了成形不足区,反映板
料变形不足,可能引起冲压件刚性不足、鼓动或产生表面微波纹现象,更加方便地
对于汽车外覆盖件进行成形性分析。
通过大量的系统测试和实际工业应用,验证了所开发的后处理系统的稳定性和
实用性,基本满足有限元模拟后处理的需要。
Sheet metal stamping process is widely used in automobile, aircraft, shipbuilding,
household appliance and other industries with high production efficiency, good product
performance and work material saving. Especially, in the automobile manufacture
industry, most pieces of an automobile are made with stamping process. The cover piece
product is the key link in the automobile product development, which is endowed with the
vivid characters of short market life cycle, large physical dimension, form changing
frequently, high forming quality requirements.
At the product design stage, it is hard to evaluate forming process and quality of the
product effectively. Traditionally, both cover piece product finished and die designed
mostly depend on experience and die setting. So, it is urgent necessary to have a kind of
operative analysis method to instruct product design. The finite element inverse approach
can simulate numerically product forming well and become gradually a useful analysis
method at the cover piece development stage of a new automobile. It is very useful that
the approach can analyze and evaluate the product subsequent process usability, shorten
product development cycle, reduce the manufacturing cost at the stage.
Related algorithm problems are studied in the pre and post process subsystem of the
finite element simulation system, FASTAMP, which is based on inverse approach and
developed by State Key Laboratory of Plastic Forming Simulation and Die & Mould
Technology, HUST. And the post process system of FASTAMP is developed.
In the pre process system, the quality of element meshed is checked. A new searching
algorithm is proposed which can build the element topological connection relationship
quickly. Based on the relationship, the element deficiencies such as duplicate element, and
an element edge shared by many elements are checked and recovered. According to the
requirement of the calculation, the functions that can reverse the element normal direction
automatically and check element negative angle dynamically, are completed.
In the post system, the physical quantity distribution displaying algorithms of finite
element analysis are studied, and three algorithms of element mode, contour mode and
section mode are achieved. A new contour algorithm based on dynamically partitioning
physical quantity distribution zone, is proposed, which can execute quickly and efficiently.
According to the requirement of the post system, a displaying algorithm about physical
quantity distribution in a section is proposed. And then the merits and demerits of the
three modes are compared.
II
The foundation of Forming Limit Diagram(FLD) is studied from two aspect of
theory and experiment. The Wrinkle Limit Diagram is introduced to extend the
conventional FLD. Then the new FLD can reflect not only the tendency of the reducing in
thickness and the fracture but also the tendency of the wrinkling up relatively right. At the
meantime, the insufficient forming area is introduced to reflect the phenomenon of the
insufficient rigidity of stamped product, bulging, micro ripple, which are caused by the
insufficient forming. So the final FLD can analyze the forming of an automobile cover
piece easily.
Through the many system test and practical industrial application, the stability and
practicability of the post process subsystem is demonstrated. And the functions of the
system meet the need of the finite element analysis.
引文
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Vol.9:143~155
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Large Strain and Large Displacement, International Journal of Solids and Structures,
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压技术,2002,2:23~26
[2] 梁炳文、胡世光.板料成形塑性理论. 北京:机械工业出版社,1987
[3] 杨玉英,大型薄板成形技术. 北京:国防工业出版社,1996
[4] 王祖唐,关延栋,肖景容. 金属塑性成形原理. 北京:机械工业出版社,1989
[5] 李尚健.金属塑性成形过程模拟. 北京:机械工业出版社,1999年
[6] 霍同如,徐秉业,宋军.板料成形有限元数值模拟的研究进展.力学进
展,1996,26(3):379~380
[7] 王勖成、邵敏.有限元单元法基本原理和数值方法(第二版). 北京:清华大学出版
[8] Marcal P.V., King I.P., Elastic-Plastic Analysis of Tow-Dimension Systems By the
Finite Element Method, International Journal of Mechanical Science, 1967,
Vol.9:143~155
[9] Hibbit H.D., Marcal P.V., Rice J.R. a Finite Element Formulation For Problems of
Large Strain and Large Displacement, International Journal of Solids and Structures,
1970, Vol. 6:1069~1071
[10] Wang N.M., Budiansky B., Analysis of Sheet Metal Stamping by a Finite Method,
Journal Applied Mechanics, 1978, 45(1):73~82
[11] 李晓星. 板材成形模拟的研究和应用. 金属成形工艺,2003,21(2):6~9
[12] Engineering Technology Associates,Inc. eta/DYNAFORM User’s Manual version
5.0 , 2000.
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