单搭自冲铆接头机械性能研究
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摘要
由于对能源节约型交通运输工具的迫切需求,轻量化结构(如汽车壳体)设计的需求也随之增加,这些结构常常需要使用轻型材料。对于轻型材料的连接,使用传统的点焊连接工艺十分困难,有些是不可行的。自冲铆接技术对于轻型材料的连接是一种高效的连接方法。本文主要对单搭自冲铆接头的机械性能进行探讨。
利用ANSYS有限元软件研究单搭自冲铆接头的机械性能,包括静力分析、动力分析及疲劳分析。疲劳分析利用ANSYS/FE-SAFE的分析计算功能和ANSYS的后处理功能进行联合的仿真分析,计算结果较为准确。
通过静力分析得出最大应力主要分布在上板与铆钉头部相接触的位置,及上下两板相互接触靠近铆钉孔的位置；静力分析为疲劳分析提供节点的应力信息,即静力分析结果文件(.rst)。通过拉伸实验研究单搭自冲铆接及单搭压印连接的机械性能。
对模态振型的分析,可知横向振动的奇数振型关于两板搭接位置对称,并且搭接位置处在振型的峰值处；扭转振型的偶数振型两板搭接位置扭转严重；说明两板搭接位置对单搭自冲铆接的动态性能影响较大,是疲劳分析的关键位置。
由铝合金5754单搭自冲铆接头的疲劳性能分析,得出疲劳破坏常常在上板与铆钉头部接触并靠近铆钉孔的位置,及上下两板相互接触靠近铆钉孔的位置。利用FE-SAFE软件中提供的不同阶段表面粗糙度值,分别计算得出表面粗糙度与疲劳寿命和安全系数的关系曲线,这样可以准确分析粗糙度值对疲劳寿命和安全系数的影响,粗糙度的增加使疲劳寿命降低。对不同约束条件下,单搭自冲铆接头疲劳强度的分析可知,在疲劳寿命达到一百万次以上时,单搭自冲铆接头在剪切应力下的疲劳强度远大于拉伸应力下的疲劳强度。另外本文通过对AL1100-T6, AL2024-T351,AL2014.T6和AL5754-O不同型号铝合金单搭自冲铆接的疲劳强度分析,得出AL2024-T351的疲劳性能最好,然后是AL2014-T6和AL5754-O: AL1100-T6的疲劳性能最差,而AL2014-T6和AL5754-0的疲劳性能较接近。
本文的主要目的是建立单搭自冲铆接的有限元模型,研究其机械性能,并为进一步的研究提供参考。
Due to the urgent demand for energy-efficient vehicles, there is an increasing need to design lightweight structures such as vehicle body shells, and these invariably use lightweight materials which are difficult or impossible to weld. Self-piercing riveting technology is an efficient method of connection for lightweight materials. In this paper, the mechanical properties of single lap-jointed self-piercing riveted (SPR) joints were studied.
In this thesis, finite element analysis (FEA) model of a single-lap jointed SPR joint was established, including the static analysis, dynamic analysis and fatigue analysis. In order to get accurate simulation results, a joint simulation of fatigue analysis was done by using ANSYS and FE-SAFE analysis of post-processing modules.
The static analysis of riveted connections indicate high tensile stress concentrations in the upper sheet hole, near the faying surface. Static analysis provides the information of stress on the nodes for fatigue analysis. The mechanical behavior of a single lap-jointed SPR and a single lap-jointed clinched joints under the static loads was studied by experiments.
The mode shapes show that odd mode shapes of transverse free vibration were found to be symmetrical about the mid-length position and at the peak of the mode shapes; and for even mode shapes of torsional free vibration were found the mode shape at the lap joint was somewhat distorted. Thus, the lap joint is very important and has a very significant effect on the dynamic response of joints. The lap-joint is crucial positions in the fatigue analysis.
Through the simulation of fatigue of a single lap-jointed aluminum 5754 SPR joint, fatigue damage was found on the faying surface of upper sheet, adjacent to the hole, and on the contact surface between upper sheet and lower sheet. In order to reveal the influence on the fatigue life and safety roughness caused by surface roughness, different of surface roughness were studied in this thesis, and got the plot of fatigue life versus surface roughness and safety coefficient versus fatigue life. The analysis of a single lap-jointed SPR joint at different constraints reveal that the fatigue strength under shear stress is higher than that under tensile stress. The fatigue performance of different aluminum (AL2024-T351, AL1100-T6, AL2014-T6 and AL5754-O) were also studied. The results indicate that the fatigue characteristic of AL2024-T351 is the best, which is followed by AL2014-T6 and AL5754-O.The fatigue property of AL1100-T6 was the worst. The fatigue properties of AL2014-T6 and AL5754-O are similar.
The main goal of this thesis is to establish the FEA models, investigate the mechanical properties of the single lap-jointed SPR joint and to provide a referenced for further research.
利用ANSYS有限元软件研究单搭自冲铆接头的机械性能,包括静力分析、动力分析及疲劳分析。疲劳分析利用ANSYS/FE-SAFE的分析计算功能和ANSYS的后处理功能进行联合的仿真分析,计算结果较为准确。
通过静力分析得出最大应力主要分布在上板与铆钉头部相接触的位置,及上下两板相互接触靠近铆钉孔的位置；静力分析为疲劳分析提供节点的应力信息,即静力分析结果文件(.rst)。通过拉伸实验研究单搭自冲铆接及单搭压印连接的机械性能。
对模态振型的分析,可知横向振动的奇数振型关于两板搭接位置对称,并且搭接位置处在振型的峰值处；扭转振型的偶数振型两板搭接位置扭转严重；说明两板搭接位置对单搭自冲铆接的动态性能影响较大,是疲劳分析的关键位置。
由铝合金5754单搭自冲铆接头的疲劳性能分析,得出疲劳破坏常常在上板与铆钉头部接触并靠近铆钉孔的位置,及上下两板相互接触靠近铆钉孔的位置。利用FE-SAFE软件中提供的不同阶段表面粗糙度值,分别计算得出表面粗糙度与疲劳寿命和安全系数的关系曲线,这样可以准确分析粗糙度值对疲劳寿命和安全系数的影响,粗糙度的增加使疲劳寿命降低。对不同约束条件下,单搭自冲铆接头疲劳强度的分析可知,在疲劳寿命达到一百万次以上时,单搭自冲铆接头在剪切应力下的疲劳强度远大于拉伸应力下的疲劳强度。另外本文通过对AL1100-T6, AL2024-T351,AL2014.T6和AL5754-O不同型号铝合金单搭自冲铆接的疲劳强度分析,得出AL2024-T351的疲劳性能最好,然后是AL2014-T6和AL5754-O: AL1100-T6的疲劳性能最差,而AL2014-T6和AL5754-0的疲劳性能较接近。
本文的主要目的是建立单搭自冲铆接的有限元模型,研究其机械性能,并为进一步的研究提供参考。
Due to the urgent demand for energy-efficient vehicles, there is an increasing need to design lightweight structures such as vehicle body shells, and these invariably use lightweight materials which are difficult or impossible to weld. Self-piercing riveting technology is an efficient method of connection for lightweight materials. In this paper, the mechanical properties of single lap-jointed self-piercing riveted (SPR) joints were studied.
In this thesis, finite element analysis (FEA) model of a single-lap jointed SPR joint was established, including the static analysis, dynamic analysis and fatigue analysis. In order to get accurate simulation results, a joint simulation of fatigue analysis was done by using ANSYS and FE-SAFE analysis of post-processing modules.
The static analysis of riveted connections indicate high tensile stress concentrations in the upper sheet hole, near the faying surface. Static analysis provides the information of stress on the nodes for fatigue analysis. The mechanical behavior of a single lap-jointed SPR and a single lap-jointed clinched joints under the static loads was studied by experiments.
The mode shapes show that odd mode shapes of transverse free vibration were found to be symmetrical about the mid-length position and at the peak of the mode shapes; and for even mode shapes of torsional free vibration were found the mode shape at the lap joint was somewhat distorted. Thus, the lap joint is very important and has a very significant effect on the dynamic response of joints. The lap-joint is crucial positions in the fatigue analysis.
Through the simulation of fatigue of a single lap-jointed aluminum 5754 SPR joint, fatigue damage was found on the faying surface of upper sheet, adjacent to the hole, and on the contact surface between upper sheet and lower sheet. In order to reveal the influence on the fatigue life and safety roughness caused by surface roughness, different of surface roughness were studied in this thesis, and got the plot of fatigue life versus surface roughness and safety coefficient versus fatigue life. The analysis of a single lap-jointed SPR joint at different constraints reveal that the fatigue strength under shear stress is higher than that under tensile stress. The fatigue performance of different aluminum (AL2024-T351, AL1100-T6, AL2014-T6 and AL5754-O) were also studied. The results indicate that the fatigue characteristic of AL2024-T351 is the best, which is followed by AL2014-T6 and AL5754-O.The fatigue property of AL1100-T6 was the worst. The fatigue properties of AL2014-T6 and AL5754-O are similar.
The main goal of this thesis is to establish the FEA models, investigate the mechanical properties of the single lap-jointed SPR joint and to provide a referenced for further research.
引文
[1]刘瑞军,李双义,张连洪等.自冲铆接技术在汽车车身轻量化中的应用.汽车技术,2004,(11)：33-37
[2]He Xiaocong,Ian Pearson,Ken Young.Self-pierce riveting for sheet materials:State of the art.Journal of Materials Processing Technology,2008,199(1):27-36
[3]赵少汴.抗疲劳设计.北京：机械工业出版社,1994.1
[4]Wayne.Cai,P.C.Wang,WuYang..Assembly dimensional prediction for self-piercing riveted aluminum panels.International Journal of Machine Tools& Manufacture, 2005,21(45):695-704
[5]李晓静.半空心铆钉自冲铆接工艺的研究[硕士学位论文].天津,天津大学机械工程学院,2005.1
[6]岁波,都东,常保华等.铝合金板自冲铆连接过程的模拟分析材.料科学与工艺,2007,15(5)：713-717
[7]黄志超,占金青,陈伟.半空心铆钉自冲铆接工艺过程的数值模拟.锻压技术,2007,32(5)：54-57
[8]Hahn.Ortwin,Meschut.Gerson,Peetz.Arrmin..Mechanical properties of punch rivet ed and adhesive-bonded aluminum sheets. Welding and Cutting,1999,51(7):85-95
[9]M.Fu,P.K.Mallick..Effect of process variables on the static and fatigue properties of self-piercing riveted joints in aluminum alloy 5754.Society of Automotive Engineers,2001,38(1):95-99
[10]M.Fu,P.K.Mallick.Fatigue of self-piercing riveted joints in aluminum alloy 6111. International Journal of Machine Tools&Manufacture,2005,45(3):695-704
[11]K.Lyer,F.L.Briyyman,S.J.Hu.eatl. Fatigue and fretting of self-piercing riveted joints. American Society of Mechanical Engineers,2002,13(4):401-415
[12]Christian. Westerberg.Finite Element Simulation of Crash Testing of Self-Piercing Rivet Joints.Peel Specimen[Master Dissertation].Sweden,Lund University,2002
[13]C.Westerberg.Finite element simulation of crash testing of Self-Piercing Rivet Joints.Peel specimen,Report IM-2002-020[R]. Institute for Metals Research, Sweden,2002
[14]P.J.E.Forsyth.Occurrence of fretting fatigue in practice.Fretting Fatigue,1981, 45(2):99-125
[15]lyer.Kaushik,Xue.Mianqui,Kasinadhuni.Ravindra.etal.Contribution of fretting to the fatigue and corrosive deterioration of a riveted lap jo int. Structural Integrity in Aging Aircraft,1995,47(4):35-61
[16]XinSun,Elizabeth.V.Stephens, Moe A.Khaleel.. Fatigue behaviors of self-piercing rivets joining similar and dissimilar sheet metals. International Journal of Fatigue,2007,29(2):370-386
[17]He Xiaocong,Pearson.lan,Young.ken..Free vibration characteristics of SPR joints. In:Proceedings of 8th Biennial ASME Conference on Engineering Systems Design and Analysis,ESDA2006,Torino.Italy,2006
[18]He Xiaocong,Zhu Xunzhi,Dong Biao.Transverse free vibration analysis of hybrid SPR steel joints.In:Proceedings of the 2010 International Conference Mechanical, Industrial,and Manufacturing Technologies,MIMT2010,Sanya.China,2010
[19]E.Stromstedt.Finite element simulation of crash testing of self-piercing rivet lap shear joint specimen.In:Institute for Metals Research,Sweden,2002
[20]He Xiaocong,Pearson.Ian,Young.ken.. Finite element analysis of self-piercing riveted joints. In:Sheet Metal 2007:Proceedings of the 12th International Conference,2007,344:663-668
[21]K.Iyer,S.J.Hu,F.L.Brittman.etal.Fatigue of single-and dobuble-rivet selfp-iercing riveted lap joints. Fatigue&Fracture of Engineering Materials & Struc-tures, 2005,28(11):997-1007
[22]Min.Gun Kim,Jin.Hak Kim,Kun.Chan Lee.etal..Assessment for structural stiffen-, ss and fatigue life on self-piercing rivet of car bodies.Key Engineering Materi-als,2005,297-300IV:2519-2524
[23]Lim.Bok.Kyu.Analysis of fatigue life of SPR (Self-Piercing Riveting) jointed various specimens using FEM. In:International Welding/Joining Conference, Korea,2007.5.10
[24]Khezri.R.Finite element simulation of crash testing of self-piercing riveting of deep drawing and rephosphorized sheet steel.In:Swedish Institute for Metal Research Report,Swedish,2000
[25]Sui.Bo,Du.Dong,Chang.Baohua..Finite element analysis of self-piercing riveting process.Amercian Society of Mechanical Engineers,Design Engineering Divison (Publication)DE,2004,117:149-160
[26]K.lyer,F.L.Brittman,S.J.Hu.etal..Fatigue and fretting of self-piercing riveted join-ts. Am Soc Mech Eng Manuf Eng Div MED,2002,13:40.1-415
[27]张国瑞.有限元法.北京：机械工业出版社,1991.2
[28]张洪信,赵清海ANSYS有限元分析完全自学手册.北京：机械工业出版 社,2008.3
[29]张朝ANSYS11.0结构分析工程应用实例解析.北京：机械工业出版社,2008
[30]林循泓.振动模态参数识别及其应用.南京：东南大学出版社,1994.12
[31]傅志方.振动模态分析与参数识别.北京：机械工业出版社,1990
[32]管迪华.模态分析技术.北京：清华大学出版社,1996.5
[33]曹树谦,张文德,萧龙翔.振动结构模态分析：理论,试验与应用.天津：天津大学出版社,2001
[34]袁熙,李舜酩.疲劳寿命预测方法的研究现状与发展.航空制造技术,2005,(12)：80-84
[35]李舜酩.机械疲劳与可靠性设计.北京：科学出版社,2006.9
[36]姚卫星.结构疲劳寿命分析.北京：国防工业出版社,2003
[37]张林波,柳杨,黄鹏程等.有限元疲劳分析法在汽车工程中的应用.计算机辅助工程,2006,15(z1)：195-198
[38]M.Haiba,D.C.Barton,P.C.Brooks.etal.Review of life assessment techniques appli-ed to dynamically loaded automotive components. Computers and Structures, 2002,(80):481-494
[39]傅祥炯.结构疲劳与断裂.西安：西北工业大学出版社,1995.12
[40]曾春华,邹十践.疲劳分析方法及应用.北京：国防工业出版社,1991.2
[41]刘义伦.工程构件疲劳寿命预测理论方法.湖南：湖南科学技术出版社,1997
[42]姜年朝ANSYS和ANSYS,FE-SAFE软件工程应用实例.南京：河海大学出版社,2006.7
[43]李晓静,李晓雷.汽车制造业中自冲铆接的新型连接工艺初探.天津职业院校联合学报,2007,9(5)：16-18
[2]He Xiaocong,Ian Pearson,Ken Young.Self-pierce riveting for sheet materials:State of the art.Journal of Materials Processing Technology,2008,199(1):27-36
[3]赵少汴.抗疲劳设计.北京：机械工业出版社,1994.1
[4]Wayne.Cai,P.C.Wang,WuYang..Assembly dimensional prediction for self-piercing riveted aluminum panels.International Journal of Machine Tools& Manufacture, 2005,21(45):695-704
[5]李晓静.半空心铆钉自冲铆接工艺的研究[硕士学位论文].天津,天津大学机械工程学院,2005.1
[6]岁波,都东,常保华等.铝合金板自冲铆连接过程的模拟分析材.料科学与工艺,2007,15(5)：713-717
[7]黄志超,占金青,陈伟.半空心铆钉自冲铆接工艺过程的数值模拟.锻压技术,2007,32(5)：54-57
[8]Hahn.Ortwin,Meschut.Gerson,Peetz.Arrmin..Mechanical properties of punch rivet ed and adhesive-bonded aluminum sheets. Welding and Cutting,1999,51(7):85-95
[9]M.Fu,P.K.Mallick..Effect of process variables on the static and fatigue properties of self-piercing riveted joints in aluminum alloy 5754.Society of Automotive Engineers,2001,38(1):95-99
[10]M.Fu,P.K.Mallick.Fatigue of self-piercing riveted joints in aluminum alloy 6111. International Journal of Machine Tools&Manufacture,2005,45(3):695-704
[11]K.Lyer,F.L.Briyyman,S.J.Hu.eatl. Fatigue and fretting of self-piercing riveted joints. American Society of Mechanical Engineers,2002,13(4):401-415
[12]Christian. Westerberg.Finite Element Simulation of Crash Testing of Self-Piercing Rivet Joints.Peel Specimen[Master Dissertation].Sweden,Lund University,2002
[13]C.Westerberg.Finite element simulation of crash testing of Self-Piercing Rivet Joints.Peel specimen,Report IM-2002-020[R]. Institute for Metals Research, Sweden,2002
[14]P.J.E.Forsyth.Occurrence of fretting fatigue in practice.Fretting Fatigue,1981, 45(2):99-125
[15]lyer.Kaushik,Xue.Mianqui,Kasinadhuni.Ravindra.etal.Contribution of fretting to the fatigue and corrosive deterioration of a riveted lap jo int. Structural Integrity in Aging Aircraft,1995,47(4):35-61
[16]XinSun,Elizabeth.V.Stephens, Moe A.Khaleel.. Fatigue behaviors of self-piercing rivets joining similar and dissimilar sheet metals. International Journal of Fatigue,2007,29(2):370-386
[17]He Xiaocong,Pearson.lan,Young.ken..Free vibration characteristics of SPR joints. In:Proceedings of 8th Biennial ASME Conference on Engineering Systems Design and Analysis,ESDA2006,Torino.Italy,2006
[18]He Xiaocong,Zhu Xunzhi,Dong Biao.Transverse free vibration analysis of hybrid SPR steel joints.In:Proceedings of the 2010 International Conference Mechanical, Industrial,and Manufacturing Technologies,MIMT2010,Sanya.China,2010
[19]E.Stromstedt.Finite element simulation of crash testing of self-piercing rivet lap shear joint specimen.In:Institute for Metals Research,Sweden,2002
[20]He Xiaocong,Pearson.Ian,Young.ken.. Finite element analysis of self-piercing riveted joints. In:Sheet Metal 2007:Proceedings of the 12th International Conference,2007,344:663-668
[21]K.Iyer,S.J.Hu,F.L.Brittman.etal.Fatigue of single-and dobuble-rivet selfp-iercing riveted lap joints. Fatigue&Fracture of Engineering Materials & Struc-tures, 2005,28(11):997-1007
[22]Min.Gun Kim,Jin.Hak Kim,Kun.Chan Lee.etal..Assessment for structural stiffen-, ss and fatigue life on self-piercing rivet of car bodies.Key Engineering Materi-als,2005,297-300IV:2519-2524
[23]Lim.Bok.Kyu.Analysis of fatigue life of SPR (Self-Piercing Riveting) jointed various specimens using FEM. In:International Welding/Joining Conference, Korea,2007.5.10
[24]Khezri.R.Finite element simulation of crash testing of self-piercing riveting of deep drawing and rephosphorized sheet steel.In:Swedish Institute for Metal Research Report,Swedish,2000
[25]Sui.Bo,Du.Dong,Chang.Baohua..Finite element analysis of self-piercing riveting process.Amercian Society of Mechanical Engineers,Design Engineering Divison (Publication)DE,2004,117:149-160
[26]K.lyer,F.L.Brittman,S.J.Hu.etal..Fatigue and fretting of self-piercing riveted join-ts. Am Soc Mech Eng Manuf Eng Div MED,2002,13:40.1-415
[27]张国瑞.有限元法.北京：机械工业出版社,1991.2
[28]张洪信,赵清海ANSYS有限元分析完全自学手册.北京：机械工业出版 社,2008.3
[29]张朝ANSYS11.0结构分析工程应用实例解析.北京：机械工业出版社,2008
[30]林循泓.振动模态参数识别及其应用.南京：东南大学出版社,1994.12
[31]傅志方.振动模态分析与参数识别.北京：机械工业出版社,1990
[32]管迪华.模态分析技术.北京：清华大学出版社,1996.5
[33]曹树谦,张文德,萧龙翔.振动结构模态分析：理论,试验与应用.天津：天津大学出版社,2001
[34]袁熙,李舜酩.疲劳寿命预测方法的研究现状与发展.航空制造技术,2005,(12)：80-84
[35]李舜酩.机械疲劳与可靠性设计.北京：科学出版社,2006.9
[36]姚卫星.结构疲劳寿命分析.北京：国防工业出版社,2003
[37]张林波,柳杨,黄鹏程等.有限元疲劳分析法在汽车工程中的应用.计算机辅助工程,2006,15(z1)：195-198
[38]M.Haiba,D.C.Barton,P.C.Brooks.etal.Review of life assessment techniques appli-ed to dynamically loaded automotive components. Computers and Structures, 2002,(80):481-494
[39]傅祥炯.结构疲劳与断裂.西安：西北工业大学出版社,1995.12
[40]曾春华,邹十践.疲劳分析方法及应用.北京：国防工业出版社,1991.2
[41]刘义伦.工程构件疲劳寿命预测理论方法.湖南：湖南科学技术出版社,1997
[42]姜年朝ANSYS和ANSYS,FE-SAFE软件工程应用实例.南京：河海大学出版社,2006.7
[43]李晓静,李晓雷.汽车制造业中自冲铆接的新型连接工艺初探.天津职业院校联合学报,2007,9(5)：16-18