聚碳酸酯汽车玻璃热态气压胀形工艺参数及数值模拟研究
|
摘要
伴随汽车行业的飞速发展,安全性及轻量化已经成为现代汽车制造业追求的主要目标之一,而汽车玻璃是关系到汽车安全性的一个重要方面。聚碳酸酯(polycarbonate,简称PC)以其良好的透光性、耐候性、柔韧性,较高冲击强度及较小的比重等综合性能成为汽车玻璃首选的替代品。然而传统的注塑、挤出等加工方法对加工此类大尺寸复杂形面PC汽车玻璃制件显得无能为力,因此探索热态气压胀形的方法加工此类大尺寸复杂形面PC汽车玻璃制件有着重要意义。
本文首先进行了不同温度、不同应变速率组合下的PC板材高温拉伸试验,获得了其力学性能参数。根据PC板材高温拉伸试验结果,研究了温度及应变速率对PC板料力学性能的影响规律,获得PC板材热气压胀形最佳工艺参数组合。
根据PC板材高温拉伸试验结果,建立了PC高温塑性本构方程,为PC板材热态气压胀形数值模拟提供了理论依据。
鉴于PC汽车玻璃形面的复杂性,根据其几何形状建立了三种不同工艺补充形式的热气压胀形有限元模型。通过对PC汽车玻璃数值模拟及结果分析,以切边后PC汽车玻璃制件壁厚均匀性、脱模后残余变形为评价指标对上述三种模型进行优选,为以后PC汽车玻璃胀形提供了最佳有限元模型。
利用Dynaform软件对PC汽车玻璃热态气压胀形进行了数值模拟研究了,获得了气压力、压边力、摩擦系数等工艺参数对PC汽车玻璃的厚度分布及回弹等的影响规律。
采用正交优化方法对气压力、压边力、摩擦系数进行参数优选,通过极差分析及方差分析获得最佳工艺参数组合及各工艺参数对PC汽车制件壁厚不均匀性、减薄率及回弹量影响的显著性,为以后实际加工提供了参考。
利用最佳工艺参数组合下的回弹结果对PC胀形模具进行了模面修正,为以后加工PC汽车玻璃制件提供了良好的成形模具。
With the rapid development of the automotive industry, safety and lightweight has become one of the main objectives for modern automobile manufacturing industry. Moreover, automotive glass is one of most important aspect related to auto safety. PC (polycarbonate, PC) with a good transparency, weather ability, flexibility, high impact strength and a smaller density and so on. Those integrated performance makes PC become the first replacement choice for automotive glass. However, the traditional injection molding, extrusion and other processing methods can not process such large-size complex-shaped PC plastic windows, so explore hot air bulge-forming to process such large complex shape of PC automotive glass parts is of great significance.
This paper firstly does the high temperature tensile test of PC sheet under combinations of different temperatures and different strain rates. According to the high temperature tensile test, the law of temperature and strain rate to the mechanical properties for PC and technical parameters for PC hot air bulge-forming were obtained.
According to tensile test of PC sheet under high temperature, PC high-temperature plastic constitutive equation is established which provides a theoretical basis for the numerical simulation of hot air bulge-forming.
Owing to the complexity of PC automotive glass, three finite element models of different addendum and binder surface were established. According to the numerical simulation results using thickness uniformity、stripping residual deformation evaluate the three models above, the best model was selected.
PC automotive glass bugle-forming was simulated by the software DYNAFORM. The effect of the process parameters including gas pressure、binder force、friction factor and so on were obtained.
Gas pressure、binder force and friction factor was selected using orthogonal optimization. The prominence of process parameters were analyzed through variance analysis and range analysis, which provide a reference for the actual processing.
The result of spring under the best combination of technical parameters was used for die amendment, which provides the best die for PC auto glass work piece.
本文首先进行了不同温度、不同应变速率组合下的PC板材高温拉伸试验,获得了其力学性能参数。根据PC板材高温拉伸试验结果,研究了温度及应变速率对PC板料力学性能的影响规律,获得PC板材热气压胀形最佳工艺参数组合。
根据PC板材高温拉伸试验结果,建立了PC高温塑性本构方程,为PC板材热态气压胀形数值模拟提供了理论依据。
鉴于PC汽车玻璃形面的复杂性,根据其几何形状建立了三种不同工艺补充形式的热气压胀形有限元模型。通过对PC汽车玻璃数值模拟及结果分析,以切边后PC汽车玻璃制件壁厚均匀性、脱模后残余变形为评价指标对上述三种模型进行优选,为以后PC汽车玻璃胀形提供了最佳有限元模型。
利用Dynaform软件对PC汽车玻璃热态气压胀形进行了数值模拟研究了,获得了气压力、压边力、摩擦系数等工艺参数对PC汽车玻璃的厚度分布及回弹等的影响规律。
采用正交优化方法对气压力、压边力、摩擦系数进行参数优选,通过极差分析及方差分析获得最佳工艺参数组合及各工艺参数对PC汽车制件壁厚不均匀性、减薄率及回弹量影响的显著性,为以后实际加工提供了参考。
利用最佳工艺参数组合下的回弹结果对PC胀形模具进行了模面修正,为以后加工PC汽车玻璃制件提供了良好的成形模具。
With the rapid development of the automotive industry, safety and lightweight has become one of the main objectives for modern automobile manufacturing industry. Moreover, automotive glass is one of most important aspect related to auto safety. PC (polycarbonate, PC) with a good transparency, weather ability, flexibility, high impact strength and a smaller density and so on. Those integrated performance makes PC become the first replacement choice for automotive glass. However, the traditional injection molding, extrusion and other processing methods can not process such large-size complex-shaped PC plastic windows, so explore hot air bulge-forming to process such large complex shape of PC automotive glass parts is of great significance.
This paper firstly does the high temperature tensile test of PC sheet under combinations of different temperatures and different strain rates. According to the high temperature tensile test, the law of temperature and strain rate to the mechanical properties for PC and technical parameters for PC hot air bulge-forming were obtained.
According to tensile test of PC sheet under high temperature, PC high-temperature plastic constitutive equation is established which provides a theoretical basis for the numerical simulation of hot air bulge-forming.
Owing to the complexity of PC automotive glass, three finite element models of different addendum and binder surface were established. According to the numerical simulation results using thickness uniformity、stripping residual deformation evaluate the three models above, the best model was selected.
PC automotive glass bugle-forming was simulated by the software DYNAFORM. The effect of the process parameters including gas pressure、binder force、friction factor and so on were obtained.
Gas pressure、binder force and friction factor was selected using orthogonal optimization. The prominence of process parameters were analyzed through variance analysis and range analysis, which provide a reference for the actual processing.
The result of spring under the best combination of technical parameters was used for die amendment, which provides the best die for PC auto glass work piece.
引文
1.黄锐.塑料工程手册.机械工业出版社,2000:1~6.
2.白杉等.聚碳酸酯的技术进展与市场开拓.化学与粘合,2004,5:287~290.
3.章文.聚碳酸酯的产需分析.上海化工,2004,2:50.
4.史国力,李复生,田红兵.聚碳酸酯在汽车和航空透明材料领域应用的研究进展.材料导报. 2006,20(5):404~407
5.吴景诚.聚碳酸酯车窗开发技术及展望.中国塑料信息,2002,2:1~2
6. K.Ito. New Model Materials for Photo elasticity and Photo plasticity. Exp. Mech,1962,2(12):373~376.
7. W.A.Brill. Basic Studies in Photo plasticity. Ph. D. Thesis,Stanford University,1965.
8. J.W.Dally. Polycarbonate as a Model Material for Three dimensional Photo plasticity. Trans.ASMEof Appl. Mech,1973:600~605.
9. M.L .Bisilliat,N.Billon.Rheology of a solid polycarbonate at high strain rate. Experimental study and numerical simulation, 5th Europe.Rheology Conf., Portoroz, Slovénie, 6-11 September 1998.
10. P.A.Oconnell.Time-Temperature and Time-Strain Superposition in Polycarbonate Below Tg . American Chemical Society Meeting, San Francisco, CA, 4/15/97.
11.朱明海,范琳.光塑性模型材料聚碳酸酯的光学、力学性能.材料科学与工程,1990,8(2):36~41.
12.卢子兴.聚碳酸酯微孔泡沫塑料及其基体材料的拉伸力学性能.中国塑料,2002, 16(9):53~56.
13.刘涛,罗世凯,余雪江.聚碳酸酯微孔泡沫塑料力学性能的研究.塑料科技.2008,2(32):60~65
14.胡文军,张方举,田常津,刘占方,陈勇梅,孙敏.载荷作用下聚碳酸酯试件温升的实验研究.高分子材料科学与工程.2007,3(23):199~201
15. Young-Kuk Choi . Production and characterization of polycarbonate composite sheets reinforced with vapor grown carbon fiber Composites. 2006,37:1944–1951
16. A.Eitan, F.T.Fisher, R.Andrews, L.C.Brinson, L.S.S chadler. Reinforcement mechanisms in MWCNT-filled polycarbonate. Composites Science and Technology. 2006,26: 1159–1170
17. Naylor Sardinha de Melo,Ricardo Ponde Weber,Joao Carlos Miguez Suarez. Toughness behavior of gamma-irradiated polycarbonate. Polymer Testing.2007,26 :315–322
18.郑怡磊,李远莉,刘欣,刘正英,杨伟,李尉,杨鸣波.聚碳酸酯/羟基磷灰石纳米复合材料的力学性能与热性能.高分子材料科学与工程. 2008,24(4):62~65
19.李丽,王成国,李同生,陈文忠.聚碳酸酯及聚碳酸酯合金导热绝缘高分子材料的研究.材料热处理学报. 2008,28(4):51~54
20.刘都宝,鲍俊杰,高明志,黎群,许戈文.聚碳酸酯基水性聚氨酯的合成与性能研究.化学推进剂与高分子材料.2007,5(2):49~51
21. Motschall,Erhard,Protoschill,Klaus W. Polycarbonate in Automotive Taillight and other Main Electrical Device In western Europe. Lubrication Engineering 1974 SPE Natl Tech Conf, Plast in Surf Transp, Proc 1974:74-77
22. J. Gilberts and A.H.A. Tinnemans.UV Curable Hard Transparent Hybrid Coating Materials on Polycarbonate Prepared by the Sol-Gel Method .Journal of Sol-Gel Science and Technology .1998,11:153–159
23. M. Ahmed, M.S.J. Hashmi. Finite element simulation of bulge forming of an elbow of box section from circular tube,Journal of Materials Processing Technology. 1998,77:410~418
24. M. Imaninejad, G.Subhash, A.Loukus. Experimental and numerical investigation of free-bulge formation during hydroforming of aluminum extrusions,Journal of Materials Processing Technology. 2004,147 :247–254
25. B.J. Kima. Finite element analysis and experimental confirmation of warm hydroforming process for aluminum alloy. Journal of Materials Processing Technology . 2007,188:296–299
26.张凯锋.超塑性成形的有限元分析及模具型腔超属性成形的研究.哈尔滨工业大学博士论文. 1990
27.张仲元,黄翔.TC4超塑形胀性研究.全国第五届超塑性学术讨论会论文集. 1992:259-268
28. Li Chunfeng, Zhao Zhiheng, Li Jianhui,Wang Yongzhi,Yang Yuying. Numericalsimulation of the magnetic pressure in tube electromagnetic bulging. Journal of Materials Processing Technology .2002,123:225~228
29. Yeong-Maw Hwang, Yi-Kai Lin. Analysis and finite element simulation of the tube bulge hydroforming process , Journal of Materials Processing Technology .2002,125–126:821~825
30.朱国瑞朱锡雄,朱国瑞,黄旭升,陈江瑛.玻璃态高聚物PMMA的应变软化-强化效应.高分子材料科学与工程. 1992,2:1~9
31.朱锡雄,黄旭升.高聚物PMMA的受力变形行为与粘弹塑性本构理论模型.宁波大学学报. 1996,9:56~69
32.陈江瑛,黄旭升,朱国瑞,朱国瑞.国产航空有机玻璃(PMMA)的压缩应力应变行为研究.宁波大学学报. 1991,1:77~87
33. J. Richeton, S. Ahzi, K.S. Vecchio , F.C. Jiang ,A. Makradi . Modeling and validation of the large deformation inelastic response of amorphous polymers over a wide range of temperatures and strain rates. International Journal of Solids and Structures . 2007(44): 7938–7954
34.陈如欣,胡忠明编著.塑性有限元法及其在金属成形中的应用.重庆大学出版社, 1989:57~143
35.孟凡中.弹塑性有限变形理论和有限元方法.清华大学出版社, 1985: 57~10
36.姜晋庆,张铎编著.结构弹塑性有限元分析法.宇航出版社, 1990:1~150
37.杨玉英.大型薄板成形技术.国防工业出版社.1996:212~213
38.张俊.汽车覆盖件成形数值模拟及优化技术研究.浙江大学博士学位论文.2005:63~64
39.李云燕,胡传荣.试验设计与数据处理.化学工业出版社.2005:79~80
40.杨光,胡平,吴志祥.板材冲压切边回弹有限元模拟中的切边处理技术.塑性工程学报. 2004,11(5):5~8
41.郑超.汽车后桥横梁冲压回弹控制与工艺参数优化研究.合肥工业大学硕士论文.2007,11:2~3
42. HamoudaAMS,KhadraFAbu,HamadanMMsPri . Spring back in V bending: A finite element approach (J). International Journal of Materials and Produet Teehno1Ogy,2004,21:124~136.
43.汪城,张质良.二维板料U形弯曲回弹的数值模拟研究.金属成形工艺. 1999,4:33~35
44.李春光.汽车及盖件冲压回弹与控制方法研究.吉林大学博士论文.2006,12:39~53.
2.白杉等.聚碳酸酯的技术进展与市场开拓.化学与粘合,2004,5:287~290.
3.章文.聚碳酸酯的产需分析.上海化工,2004,2:50.
4.史国力,李复生,田红兵.聚碳酸酯在汽车和航空透明材料领域应用的研究进展.材料导报. 2006,20(5):404~407
5.吴景诚.聚碳酸酯车窗开发技术及展望.中国塑料信息,2002,2:1~2
6. K.Ito. New Model Materials for Photo elasticity and Photo plasticity. Exp. Mech,1962,2(12):373~376.
7. W.A.Brill. Basic Studies in Photo plasticity. Ph. D. Thesis,Stanford University,1965.
8. J.W.Dally. Polycarbonate as a Model Material for Three dimensional Photo plasticity. Trans.ASMEof Appl. Mech,1973:600~605.
9. M.L .Bisilliat,N.Billon.Rheology of a solid polycarbonate at high strain rate. Experimental study and numerical simulation, 5th Europe.Rheology Conf., Portoroz, Slovénie, 6-11 September 1998.
10. P.A.Oconnell.Time-Temperature and Time-Strain Superposition in Polycarbonate Below Tg . American Chemical Society Meeting, San Francisco, CA, 4/15/97.
11.朱明海,范琳.光塑性模型材料聚碳酸酯的光学、力学性能.材料科学与工程,1990,8(2):36~41.
12.卢子兴.聚碳酸酯微孔泡沫塑料及其基体材料的拉伸力学性能.中国塑料,2002, 16(9):53~56.
13.刘涛,罗世凯,余雪江.聚碳酸酯微孔泡沫塑料力学性能的研究.塑料科技.2008,2(32):60~65
14.胡文军,张方举,田常津,刘占方,陈勇梅,孙敏.载荷作用下聚碳酸酯试件温升的实验研究.高分子材料科学与工程.2007,3(23):199~201
15. Young-Kuk Choi . Production and characterization of polycarbonate composite sheets reinforced with vapor grown carbon fiber Composites. 2006,37:1944–1951
16. A.Eitan, F.T.Fisher, R.Andrews, L.C.Brinson, L.S.S chadler. Reinforcement mechanisms in MWCNT-filled polycarbonate. Composites Science and Technology. 2006,26: 1159–1170
17. Naylor Sardinha de Melo,Ricardo Ponde Weber,Joao Carlos Miguez Suarez. Toughness behavior of gamma-irradiated polycarbonate. Polymer Testing.2007,26 :315–322
18.郑怡磊,李远莉,刘欣,刘正英,杨伟,李尉,杨鸣波.聚碳酸酯/羟基磷灰石纳米复合材料的力学性能与热性能.高分子材料科学与工程. 2008,24(4):62~65
19.李丽,王成国,李同生,陈文忠.聚碳酸酯及聚碳酸酯合金导热绝缘高分子材料的研究.材料热处理学报. 2008,28(4):51~54
20.刘都宝,鲍俊杰,高明志,黎群,许戈文.聚碳酸酯基水性聚氨酯的合成与性能研究.化学推进剂与高分子材料.2007,5(2):49~51
21. Motschall,Erhard,Protoschill,Klaus W. Polycarbonate in Automotive Taillight and other Main Electrical Device In western Europe. Lubrication Engineering 1974 SPE Natl Tech Conf, Plast in Surf Transp, Proc 1974:74-77
22. J. Gilberts and A.H.A. Tinnemans.UV Curable Hard Transparent Hybrid Coating Materials on Polycarbonate Prepared by the Sol-Gel Method .Journal of Sol-Gel Science and Technology .1998,11:153–159
23. M. Ahmed, M.S.J. Hashmi. Finite element simulation of bulge forming of an elbow of box section from circular tube,Journal of Materials Processing Technology. 1998,77:410~418
24. M. Imaninejad, G.Subhash, A.Loukus. Experimental and numerical investigation of free-bulge formation during hydroforming of aluminum extrusions,Journal of Materials Processing Technology. 2004,147 :247–254
25. B.J. Kima. Finite element analysis and experimental confirmation of warm hydroforming process for aluminum alloy. Journal of Materials Processing Technology . 2007,188:296–299
26.张凯锋.超塑性成形的有限元分析及模具型腔超属性成形的研究.哈尔滨工业大学博士论文. 1990
27.张仲元,黄翔.TC4超塑形胀性研究.全国第五届超塑性学术讨论会论文集. 1992:259-268
28. Li Chunfeng, Zhao Zhiheng, Li Jianhui,Wang Yongzhi,Yang Yuying. Numericalsimulation of the magnetic pressure in tube electromagnetic bulging. Journal of Materials Processing Technology .2002,123:225~228
29. Yeong-Maw Hwang, Yi-Kai Lin. Analysis and finite element simulation of the tube bulge hydroforming process , Journal of Materials Processing Technology .2002,125–126:821~825
30.朱国瑞朱锡雄,朱国瑞,黄旭升,陈江瑛.玻璃态高聚物PMMA的应变软化-强化效应.高分子材料科学与工程. 1992,2:1~9
31.朱锡雄,黄旭升.高聚物PMMA的受力变形行为与粘弹塑性本构理论模型.宁波大学学报. 1996,9:56~69
32.陈江瑛,黄旭升,朱国瑞,朱国瑞.国产航空有机玻璃(PMMA)的压缩应力应变行为研究.宁波大学学报. 1991,1:77~87
33. J. Richeton, S. Ahzi, K.S. Vecchio , F.C. Jiang ,A. Makradi . Modeling and validation of the large deformation inelastic response of amorphous polymers over a wide range of temperatures and strain rates. International Journal of Solids and Structures . 2007(44): 7938–7954
34.陈如欣,胡忠明编著.塑性有限元法及其在金属成形中的应用.重庆大学出版社, 1989:57~143
35.孟凡中.弹塑性有限变形理论和有限元方法.清华大学出版社, 1985: 57~10
36.姜晋庆,张铎编著.结构弹塑性有限元分析法.宇航出版社, 1990:1~150
37.杨玉英.大型薄板成形技术.国防工业出版社.1996:212~213
38.张俊.汽车覆盖件成形数值模拟及优化技术研究.浙江大学博士学位论文.2005:63~64
39.李云燕,胡传荣.试验设计与数据处理.化学工业出版社.2005:79~80
40.杨光,胡平,吴志祥.板材冲压切边回弹有限元模拟中的切边处理技术.塑性工程学报. 2004,11(5):5~8
41.郑超.汽车后桥横梁冲压回弹控制与工艺参数优化研究.合肥工业大学硕士论文.2007,11:2~3
42. HamoudaAMS,KhadraFAbu,HamadanMMsPri . Spring back in V bending: A finite element approach (J). International Journal of Materials and Produet Teehno1Ogy,2004,21:124~136.
43.汪城,张质良.二维板料U形弯曲回弹的数值模拟研究.金属成形工艺. 1999,4:33~35
44.李春光.汽车及盖件冲压回弹与控制方法研究.吉林大学博士论文.2006,12:39~53.