焊点排布对结构耐撞性影响的研究和应用
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摘要
点焊连接具有强度高、性能稳定、成本低等优点,因此仍被作为车身制造过程中最主要的部件连接方法。车身上往往排布着数千个焊点,由于焊点排布是非连续的,并会形成应力集中区域,这样的连接方式相当于在车辆结构中添加了一定的缺陷。因此,焊点排布情况会对车辆结构的耐撞性、耐久性以及NVH等性能产生一定的影响。
车辆乘员保护和耐撞性要求车身吸能部件能在有限的变形空间内吸收更多的能量。车身上的典型吸能结构件多数都是由焊点连接形成的帽型结构。这些结构的变形模式及吸能效率决定了车辆在不同的碰撞工况中的耐撞性能。
论文对焊点排布与典型的吸能结构(包括单帽结构、双帽结构以及曲梁)变形模式之间的关系进行了深入研究。本研究提取出决定焊点排布情况的关键参数,并通过有限元模拟方法得到了不同参数水平下的典型吸能结构变形模式及吸能情况。根据这些计算结果,同时结合塑性铰理论,从结构的变形机理出发分析了焊点排布参数对车辆中典型吸能部件变形稳定性和吸能能力的影响。通过这些研究发现,结构自身的不规则性越显著,焊点排布对其耐撞性能的影响就越小。同时,焊点排布对结构耐撞性的影响与结构所承受的载荷类型以及约束条件也有紧密联系。
另外,在现有的技术条件下,把车辆造型、性能、加工制造等作为一个整体进行优化设计仍是比较困难的。因此,在车辆设计过程中,性能设计与结构加工制造设计之间的反复循环就成为常出现的问题。在性能设计之后的加工制造设计中,如果需要根据几何上的约束等原因对已有的焊点排布进行调整,就需要重新评估结构的各项性能指标,这样的反复循环会增加设计周期和成本。在对焊点排布与典型的吸能结构变形模式之间的关系进行了深入研究的基础上,本文提出了一种考虑结构加工制造约束的焊点排布优化设计概念,在结构性能设计阶段就将加工制造约束考虑进来,可以有效解决上述问题。同时,利用准确的响应面方法,对实际车身吸能结构在不同焊点排布下的耐撞性指标进行预测,并分析比较了不同边界条件下的焊点排布敏感性情况。
Spot welding is still a commonly used joining method in vehicle structures for its advantages in stiffness, durability and cost. There are usually thousnands of welds on a signle vehicle body. These welds form discrete joining points and produce stress concentration areas on the vehicle structure. The welds to some extent may be considered as imperfections of the vehicle body. Therefore, spot weld layout is an influential factor to the crashworthiness, durability and NVH performance.
Energy absorbing structures in vehicle body are designed to absorb as much kinetic energy as possible in a limited deformation displacement for protecting the occupants. Most typical energy absorbing structures on vehicle body are close-hat thin-wall sections. The vehicle crash performance is mainly dependent on the deformation mode and energy absorbing efficiency of these structures.
In this thesis, the relationship between spot weld layout and deformation mode of typical energy absorbing structures, such as single-hat, double-hat and curved tubes, is studied. Key parameters of spot weld layout have been determined. Using finite element analysis, the deformation mode and energy absorbing characteristics under different spot weld layout design parameters have been studied. With the simulation results and the plastic hinge theory, the influence of spot weld layout on the deformation stability and energy absorbing capability of the structures has been discussed. It is found that, as the extent of the imperfections increases in the structures, the spot weld layout design would exert less influence on the structural performance. Meanwhile, the influence of spot weld layout is also closely related to the loading types and the boundary constraint conditions on the structure.
In the automotive industry, with the current technologies, it is still not possible to consider all the vehicle design aspects, such as styling, performance, manufacturability, etc., in a single design optimization process. Iterations between design for performance and design for manufacturing are typical. After the performance design, the spot weld layout in vehicle body often needs to be adjusted due to certain kind of geometrical constraints in welding process, and thus the structural performances would have to be reassessed accordingly. Such design iterations are a barrier to increasing the vehicle development efficiency and shortening the development cycle. In this thesis, a new approach has been proposed for the concept of Design for Manufacturing. The manufacturing constraints of welding are included into the structural performance design stage. With such a concept, the structural design would achieve performance in a manufacturable way and aforementioned issue could be resolved. In the meantime, the crash performance of energy absorbing structures under different spot weld layouts can be predicted through the response surfaces generated in the study. And the sensitivity of spot weld layout under different boundary conditions has also been presented.
车辆乘员保护和耐撞性要求车身吸能部件能在有限的变形空间内吸收更多的能量。车身上的典型吸能结构件多数都是由焊点连接形成的帽型结构。这些结构的变形模式及吸能效率决定了车辆在不同的碰撞工况中的耐撞性能。
论文对焊点排布与典型的吸能结构(包括单帽结构、双帽结构以及曲梁)变形模式之间的关系进行了深入研究。本研究提取出决定焊点排布情况的关键参数,并通过有限元模拟方法得到了不同参数水平下的典型吸能结构变形模式及吸能情况。根据这些计算结果,同时结合塑性铰理论,从结构的变形机理出发分析了焊点排布参数对车辆中典型吸能部件变形稳定性和吸能能力的影响。通过这些研究发现,结构自身的不规则性越显著,焊点排布对其耐撞性能的影响就越小。同时,焊点排布对结构耐撞性的影响与结构所承受的载荷类型以及约束条件也有紧密联系。
另外,在现有的技术条件下,把车辆造型、性能、加工制造等作为一个整体进行优化设计仍是比较困难的。因此,在车辆设计过程中,性能设计与结构加工制造设计之间的反复循环就成为常出现的问题。在性能设计之后的加工制造设计中,如果需要根据几何上的约束等原因对已有的焊点排布进行调整,就需要重新评估结构的各项性能指标,这样的反复循环会增加设计周期和成本。在对焊点排布与典型的吸能结构变形模式之间的关系进行了深入研究的基础上,本文提出了一种考虑结构加工制造约束的焊点排布优化设计概念,在结构性能设计阶段就将加工制造约束考虑进来,可以有效解决上述问题。同时,利用准确的响应面方法,对实际车身吸能结构在不同焊点排布下的耐撞性指标进行预测,并分析比较了不同边界条件下的焊点排布敏感性情况。
Spot welding is still a commonly used joining method in vehicle structures for its advantages in stiffness, durability and cost. There are usually thousnands of welds on a signle vehicle body. These welds form discrete joining points and produce stress concentration areas on the vehicle structure. The welds to some extent may be considered as imperfections of the vehicle body. Therefore, spot weld layout is an influential factor to the crashworthiness, durability and NVH performance.
Energy absorbing structures in vehicle body are designed to absorb as much kinetic energy as possible in a limited deformation displacement for protecting the occupants. Most typical energy absorbing structures on vehicle body are close-hat thin-wall sections. The vehicle crash performance is mainly dependent on the deformation mode and energy absorbing efficiency of these structures.
In this thesis, the relationship between spot weld layout and deformation mode of typical energy absorbing structures, such as single-hat, double-hat and curved tubes, is studied. Key parameters of spot weld layout have been determined. Using finite element analysis, the deformation mode and energy absorbing characteristics under different spot weld layout design parameters have been studied. With the simulation results and the plastic hinge theory, the influence of spot weld layout on the deformation stability and energy absorbing capability of the structures has been discussed. It is found that, as the extent of the imperfections increases in the structures, the spot weld layout design would exert less influence on the structural performance. Meanwhile, the influence of spot weld layout is also closely related to the loading types and the boundary constraint conditions on the structure.
In the automotive industry, with the current technologies, it is still not possible to consider all the vehicle design aspects, such as styling, performance, manufacturability, etc., in a single design optimization process. Iterations between design for performance and design for manufacturing are typical. After the performance design, the spot weld layout in vehicle body often needs to be adjusted due to certain kind of geometrical constraints in welding process, and thus the structural performances would have to be reassessed accordingly. Such design iterations are a barrier to increasing the vehicle development efficiency and shortening the development cycle. In this thesis, a new approach has been proposed for the concept of Design for Manufacturing. The manufacturing constraints of welding are included into the structural performance design stage. With such a concept, the structural design would achieve performance in a manufacturable way and aforementioned issue could be resolved. In the meantime, the crash performance of energy absorbing structures under different spot weld layouts can be predicted through the response surfaces generated in the study. And the sensitivity of spot weld layout under different boundary conditions has also been presented.
引文
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