发动机机体的数字化建模方法研究
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摘要
机体是发动机最重要的零件之一,其结构组成复杂、产品技术复杂、制造过程复杂。机体的数字化建模是发动机设计中成本最高周期最长的环节,是整个发动机建模和仿真分析的基础,对发动机产品成功开发有重要的影响。本文以某款轿车发动机为例,研究了机体数字化建模的相关理论和方法,主要包括以下内容:
在分析发动机机体产品结构和制造工艺的基础上,运用逆向工程的理论和方法快速获取隐藏在测量数据中的原始设计参数。
提出了基于自顶向下的设计理论的发动机机体数字化建模方法。结合自顶向下设计理论和特征建模方法,把机体划分为相对独立的多个模块,然后选择熟悉各模块制造工艺的设计师来完成了该模块的全参数化建模,获得高精度可修改的模块模型,最后将所有模块组装成为一个完整的机体数字化模型。在建模过程中考虑了制造工艺,提高了机体的可制造性,保证其在发动机系统中的可装配性。然后对建模时间进行了分析,结果表明建模时间大幅度缩短,建模精度也明显提高。
运用有限元理论对机体模型的振动模态和机体冷却水套流场进行了数字化仿真分析。分析表明机体刚度低于发动机的安全要求,群部刚度比汽缸体部分差,并给出提高群部刚度的方法。水套基本满足冷却要求,仅存在少量的局部低速流动区;水套各缸连接部位流速不是很高,不能满足大量燃烧热的冷却要求,并据此提出改进建议。
应用本文方法完成的发动机机体模型已经通过了企业的验收,并已经量产准备搭载某款国内自主研发的轿车产品。本文的研究成果,可以推广应用到发动机缸盖、变速箱等其他汽车产品中的复杂零件数字化建模,以及航空航天、能源发电等领域的复杂曲面零件的建模。
Engine block, with complicated structural features, complicated product technology and complicated manufacturing process, is one of the most important parts in engine. Engine block modeling is the highest cost and the longest period in engine design. Its digital model, which is the basis of digital analysis, has great influence on engine design. A digital modeling method on engine block is presented in this thesis. The concrete contents are as follows:
Original design parameters of engine block implicated in measurement data are obtained through reverse engineering theory after analyzing its structure and manufacturing process.
A digital modeling method based on top-down theory is put forward for engine block modeling. In this method, the engine block is divided into several modules in the first. Then, wholly parametric precise module models are to be built by chosen designer who is proficient in relative module manufacturing process. Finally, all of the modules are composed into engine block model. The manufacturability of engine block is improved by considering the manufacturing process in the period of modeling. And engine assembling capacity can be guaranteed because assembly relations in it are taken into account while modeling. An analysis on modeling time shows the modeling period of engine block is shorten greatly after using this method.
Mode of vibration and water jacket flow field of the engine block model just completed are analyzed in the guide of FEM and CFD theories. Mode analysis results show that the rigidity of engine block does not meet the safety requirements and the skirt of engine block is weaker than the upper part. Optimization design proposals are put forward. Water jacket can cool the engine block well except some local low-speed flow area according to the CFD analysis. The cooling water velocity between cylinders is a bit slow with respect to a mass of combustion heat. Optimization suggestions are also proposed for improving cooling capacity.
The engine block model completed in this thesis is inspected and accepted by enterprise. The method put forward in this thesis can be popularized to model other complex parts or systems, such as engine cylinder, transmission system and complex surface parts in fields of aerospace and energy generation etc.
在分析发动机机体产品结构和制造工艺的基础上,运用逆向工程的理论和方法快速获取隐藏在测量数据中的原始设计参数。
提出了基于自顶向下的设计理论的发动机机体数字化建模方法。结合自顶向下设计理论和特征建模方法,把机体划分为相对独立的多个模块,然后选择熟悉各模块制造工艺的设计师来完成了该模块的全参数化建模,获得高精度可修改的模块模型,最后将所有模块组装成为一个完整的机体数字化模型。在建模过程中考虑了制造工艺,提高了机体的可制造性,保证其在发动机系统中的可装配性。然后对建模时间进行了分析,结果表明建模时间大幅度缩短,建模精度也明显提高。
运用有限元理论对机体模型的振动模态和机体冷却水套流场进行了数字化仿真分析。分析表明机体刚度低于发动机的安全要求,群部刚度比汽缸体部分差,并给出提高群部刚度的方法。水套基本满足冷却要求,仅存在少量的局部低速流动区;水套各缸连接部位流速不是很高,不能满足大量燃烧热的冷却要求,并据此提出改进建议。
应用本文方法完成的发动机机体模型已经通过了企业的验收,并已经量产准备搭载某款国内自主研发的轿车产品。本文的研究成果,可以推广应用到发动机缸盖、变速箱等其他汽车产品中的复杂零件数字化建模,以及航空航天、能源发电等领域的复杂曲面零件的建模。
Engine block, with complicated structural features, complicated product technology and complicated manufacturing process, is one of the most important parts in engine. Engine block modeling is the highest cost and the longest period in engine design. Its digital model, which is the basis of digital analysis, has great influence on engine design. A digital modeling method on engine block is presented in this thesis. The concrete contents are as follows:
Original design parameters of engine block implicated in measurement data are obtained through reverse engineering theory after analyzing its structure and manufacturing process.
A digital modeling method based on top-down theory is put forward for engine block modeling. In this method, the engine block is divided into several modules in the first. Then, wholly parametric precise module models are to be built by chosen designer who is proficient in relative module manufacturing process. Finally, all of the modules are composed into engine block model. The manufacturability of engine block is improved by considering the manufacturing process in the period of modeling. And engine assembling capacity can be guaranteed because assembly relations in it are taken into account while modeling. An analysis on modeling time shows the modeling period of engine block is shorten greatly after using this method.
Mode of vibration and water jacket flow field of the engine block model just completed are analyzed in the guide of FEM and CFD theories. Mode analysis results show that the rigidity of engine block does not meet the safety requirements and the skirt of engine block is weaker than the upper part. Optimization design proposals are put forward. Water jacket can cool the engine block well except some local low-speed flow area according to the CFD analysis. The cooling water velocity between cylinders is a bit slow with respect to a mass of combustion heat. Optimization suggestions are also proposed for improving cooling capacity.
The engine block model completed in this thesis is inspected and accepted by enterprise. The method put forward in this thesis can be popularized to model other complex parts or systems, such as engine cylinder, transmission system and complex surface parts in fields of aerospace and energy generation etc.
引文
1中华人民共和国国家统计局. 2007年国民经济和社会发展统计公报.
2张志华,周松,黎苏.内燃机排放与噪声控制.哈尔滨工程大学出版社, 1999.
3杨文玉,尹周平,孙容磊.数字制造基础.北京:北京理工大学出版社, 2005.
4吴炎庭、袁卫平,内燃机噪声振动与控制,机械工业出版社,2005.
5朱义伦,邓康耀.发动机缸头冷却水流场试验研究,上海交通大学学报, 2000, 3(4).
6 Hudgens R D, Hercamp R D. A perspective on extended service internals and long life coolants for heavy duty engines [J ]. SAE Trans, 1996, 105 (3):877-887.
7师石金,王志,王建昕.发动机CAD/CFD设计技术,汽车工程, 2004, 26(5).
8陈志兰. CAD中的几何造型方法.民用飞机设计与研究, 1997(l): 19-22.
9 Medland A.Jetal. A Constraint Approach to Feature Based Design. Computer Intergraded Manufacturing, 1993, 16(l): 34-35.
10胡庆夕,秦鹏飞.面向制造基于特征的零件定义模型的研究及其应用[J].小型微型计算机系统, 2000, 20(4): 281-286.
11宋庆军.并行工程下面向制造设计的研究与应用.山东科技大学硕士毕业论文, 2004.
12 SODHI R, et al. Towards modeling of assemblies for product design [J]. Computer-Aided Design, 1994, 26(2): 85-97.
13 MANTYLAMA. Modeling system for top-down design of assembled products[J]. IBM Jour . Res. Develop., 1990, 34 (5): 635-659.
14 GUI J K, et al. Functional understanding of assembly modeling[J]. Computer-Aided Design, 1994, 26(6): 435-451.
15 RANTA M, et al. Integration of functional and featric-based product modeling-the IMS/ GNOSIS experience [J]. Computer-Aided Design, 1996, 28(5): 371-381.
16 GORTI S R, SRIRAM R. From symbol to form: a framework for conceptual design [J]. Computer-Aided Design, 1996, 28(11): 853-870.
17崔琼瑶,齐从谦.基于参数化技术的自顶向下设计及其应用.同济大学学报, 2002,
30(9).
18冯樱,刘加华,张胜兰.汽车变速器自顶向下设计方法研究.北京汽车. 2007(5).
19 Shung.H.Sung, Donald.J.Nefske, Franeis H.K.Chen and Miehael P.Famin. Development of a Engine System Model for Predieting Struetural Vibration and Radiated Noise the Running Engine, SAE paper 972039.
20杨志慧,汽车发动机机体有限元分析.武汉理工大学硕士学位论文, 2007.
21王义亮,谢友柏.主轴承力作用下的多缸内燃机机体结构动力响应分析.内燃机学报. 2002(5): 459-464
22杜发荣,姬芬竹等.内燃机机体有限元模态分析.柴油机, 2003(3): 41-42.
23 Franz Koch, Franz Maassen. Cooling system development and optimization with thecomputer code Cool. SAE paper 980245.
24 J.A.Sidders, D.G.Tilley. optimizing cooling system performance using computer simulation. SAE paper 971802.
25 W.Ichlseder, J. Hager, et al. Use of simulation tools with integrated coolant flow analysis for the cooling system design. SAE paper 971875.
26 John A Worden, Randall L.Zehr. Consideration of fluid velocity effects in the design and development of aluminum cooling system components for heavy duty diesel engines. SAE 1999-01-0128.
27常思勤,左孔天.发动机缸盖内部冷却水腔的设计与流动数值模拟[J].车用发动机, 2000(2): 25-27.
28屈盛官,孙自树等.高强化大功率柴油机冷却系统水流分布研究.华中科技大学学报:自然科学版, 2001, 29(8).
29陈群.车用柴油机冷却水套的计算流体力学分析.吉林大学博士学位论文, 2003.
30张强,李娜,王志明.车用柴油机缸盖冷却水腔的CFD分析[J].车用发动机, 2005(6): 59-62.
31 Carbone V., Carocci M., Savio E.et al. Combination of a vision system and a coordinate measuring machine for the reverse engineering of freeform surfaces. Advanced manufacturing technology. 2001, 17(4):263-271.
32 Shuh-Ren Liang, Alan C. Lin. Probe-radius compensation for 3D data points in reverse engineering. Computers in Industry, 2002, 48(1):241-251.
33 Hon-yuen Tam. Toward the uniform coverage of surface by scanning curves. Computer-Aided Design, 1999, 31(3): 585-596.
34许智钦,闫明,张宝峰等.逆向工程技术三维激光扫描测量.天津大学学报, 2001, 34(3): 404-407.
35海克斯康测量技术(青岛)有限公司.实用坐标测量技术.北京:化学工业出版社. 2007.
36黄小平.逆向工程中数据云处理关键技术研究.华中科技大学博士学位论文, 2002.
37 Huang J.-b.,Menq C.-h. Automatic CAD model reconstruction from mutipule point clouds for reverse engineering.Journal of Computing and Information Science in Engineering,2002,2(9):160～170.
38刘宇,熊有伦.基于法矢的点云拼合方法.机械工程学报, 2007, 43(8): 7-11.
39柯映林.反求工程CAD建模理论、方法和系统.北京:.机械工业出版社. 2005.
40刘文剑,金天国.产品自顶向下设计的研究现状及发展方向[J].计算机集成制造系统,2002.
41柯常忠,谢少波.基于参数化技术的自顶向下设计.中国制造业信息化, 2007, 2(3).
42 Duan W., Zhou J. , Lai K. FSMT. A Feature Solid-Modeling Tool for Feature based Design and Manufacture. Computer assisted design, 1993(1): 29-38.
43崔琼瑶,齐从谦.基于参数化技术的自顶向下设计及其应用.同济大学学报, 2002(9).
44刘辉,项昌乐,郑慕侨.模块化建模方法及其在车辆传动系中的应用.计算机仿真, 2002, 19(3): 61-67.
45 Kuo T C, Huang S H, Zhang H C. Design for manufacture and design for‘X’: concepts,applications, and Perspectives. Compute and Industrial Engineering. 2001, 41: 241-260.
46周世权,田文峰.机械制造工艺基础.武汉:华中科技大学出版社,2005.
47严蔚敏,吴伟民.数据结构(C语言版).北京:清华大学出版社, 1997.
48刘芳,王玲.基于动态规划思想求解关键路径的算法[J].计算机应用, 2006, 26(6): 1440-1442.
49刘豫,孙秦.大型结构动力特性的Lanczos数值计算方法及程序设计.科学技术与工程, 2008, 8(4).
50周宁. ANSYS机械工程应用实例.北京:中国水利水电出版社, 2006.
51丁历伟. CA4D32柴油机机体有限元动力分析.大连海事大学硕士毕业论文, 2007.
52 P.Rollet-Miet, D.Laurence, J.Ferziger. LES and RANS of turbulent flow in tube bundles. International Journal of Heat and Fluid Flow. 1999, 20(3): 241-254.
53 J.O.Hinze. Turbulent. McGraw-Hill, New York, 1975.
54 B.E.Launder, D.B.Spalding. Lectures in Mathematical Models of Turbulence. Academic Press, London, 1972.
55 V. Yakhot, S. A. Orzag, Renormalization group analysis of turbulence: basic theory. J Scient Comput. 1986, 1: 3-11.
56王福军.计算流体动力学分析——CFD软件原理与应用.北京:清华大学出版社, 2004.
57杜佳正,黄荣华,王龙飞.发动机机体缸盖冷却水CFD模拟计算与分析.柴油机设计与制造. 2007, 15(1).
58韩占忠,王敬,兰小平. FLUENT流体工程仿真计算实例与应用.北京:北京理工大学, 2004.
59王建东.某发动机冷却系统的研究.南京理工大学硕士学位论文, 2008.
60叶伊苏,辛喆.车用柴油机冷却水套的CFD分析.现代车用动力, 2008, 8(3).
2张志华,周松,黎苏.内燃机排放与噪声控制.哈尔滨工程大学出版社, 1999.
3杨文玉,尹周平,孙容磊.数字制造基础.北京:北京理工大学出版社, 2005.
4吴炎庭、袁卫平,内燃机噪声振动与控制,机械工业出版社,2005.
5朱义伦,邓康耀.发动机缸头冷却水流场试验研究,上海交通大学学报, 2000, 3(4).
6 Hudgens R D, Hercamp R D. A perspective on extended service internals and long life coolants for heavy duty engines [J ]. SAE Trans, 1996, 105 (3):877-887.
7师石金,王志,王建昕.发动机CAD/CFD设计技术,汽车工程, 2004, 26(5).
8陈志兰. CAD中的几何造型方法.民用飞机设计与研究, 1997(l): 19-22.
9 Medland A.Jetal. A Constraint Approach to Feature Based Design. Computer Intergraded Manufacturing, 1993, 16(l): 34-35.
10胡庆夕,秦鹏飞.面向制造基于特征的零件定义模型的研究及其应用[J].小型微型计算机系统, 2000, 20(4): 281-286.
11宋庆军.并行工程下面向制造设计的研究与应用.山东科技大学硕士毕业论文, 2004.
12 SODHI R, et al. Towards modeling of assemblies for product design [J]. Computer-Aided Design, 1994, 26(2): 85-97.
13 MANTYLAMA. Modeling system for top-down design of assembled products[J]. IBM Jour . Res. Develop., 1990, 34 (5): 635-659.
14 GUI J K, et al. Functional understanding of assembly modeling[J]. Computer-Aided Design, 1994, 26(6): 435-451.
15 RANTA M, et al. Integration of functional and featric-based product modeling-the IMS/ GNOSIS experience [J]. Computer-Aided Design, 1996, 28(5): 371-381.
16 GORTI S R, SRIRAM R. From symbol to form: a framework for conceptual design [J]. Computer-Aided Design, 1996, 28(11): 853-870.
17崔琼瑶,齐从谦.基于参数化技术的自顶向下设计及其应用.同济大学学报, 2002,
30(9).
18冯樱,刘加华,张胜兰.汽车变速器自顶向下设计方法研究.北京汽车. 2007(5).
19 Shung.H.Sung, Donald.J.Nefske, Franeis H.K.Chen and Miehael P.Famin. Development of a Engine System Model for Predieting Struetural Vibration and Radiated Noise the Running Engine, SAE paper 972039.
20杨志慧,汽车发动机机体有限元分析.武汉理工大学硕士学位论文, 2007.
21王义亮,谢友柏.主轴承力作用下的多缸内燃机机体结构动力响应分析.内燃机学报. 2002(5): 459-464
22杜发荣,姬芬竹等.内燃机机体有限元模态分析.柴油机, 2003(3): 41-42.
23 Franz Koch, Franz Maassen. Cooling system development and optimization with thecomputer code Cool. SAE paper 980245.
24 J.A.Sidders, D.G.Tilley. optimizing cooling system performance using computer simulation. SAE paper 971802.
25 W.Ichlseder, J. Hager, et al. Use of simulation tools with integrated coolant flow analysis for the cooling system design. SAE paper 971875.
26 John A Worden, Randall L.Zehr. Consideration of fluid velocity effects in the design and development of aluminum cooling system components for heavy duty diesel engines. SAE 1999-01-0128.
27常思勤,左孔天.发动机缸盖内部冷却水腔的设计与流动数值模拟[J].车用发动机, 2000(2): 25-27.
28屈盛官,孙自树等.高强化大功率柴油机冷却系统水流分布研究.华中科技大学学报:自然科学版, 2001, 29(8).
29陈群.车用柴油机冷却水套的计算流体力学分析.吉林大学博士学位论文, 2003.
30张强,李娜,王志明.车用柴油机缸盖冷却水腔的CFD分析[J].车用发动机, 2005(6): 59-62.
31 Carbone V., Carocci M., Savio E.et al. Combination of a vision system and a coordinate measuring machine for the reverse engineering of freeform surfaces. Advanced manufacturing technology. 2001, 17(4):263-271.
32 Shuh-Ren Liang, Alan C. Lin. Probe-radius compensation for 3D data points in reverse engineering. Computers in Industry, 2002, 48(1):241-251.
33 Hon-yuen Tam. Toward the uniform coverage of surface by scanning curves. Computer-Aided Design, 1999, 31(3): 585-596.
34许智钦,闫明,张宝峰等.逆向工程技术三维激光扫描测量.天津大学学报, 2001, 34(3): 404-407.
35海克斯康测量技术(青岛)有限公司.实用坐标测量技术.北京:化学工业出版社. 2007.
36黄小平.逆向工程中数据云处理关键技术研究.华中科技大学博士学位论文, 2002.
37 Huang J.-b.,Menq C.-h. Automatic CAD model reconstruction from mutipule point clouds for reverse engineering.Journal of Computing and Information Science in Engineering,2002,2(9):160～170.
38刘宇,熊有伦.基于法矢的点云拼合方法.机械工程学报, 2007, 43(8): 7-11.
39柯映林.反求工程CAD建模理论、方法和系统.北京:.机械工业出版社. 2005.
40刘文剑,金天国.产品自顶向下设计的研究现状及发展方向[J].计算机集成制造系统,2002.
41柯常忠,谢少波.基于参数化技术的自顶向下设计.中国制造业信息化, 2007, 2(3).
42 Duan W., Zhou J. , Lai K. FSMT. A Feature Solid-Modeling Tool for Feature based Design and Manufacture. Computer assisted design, 1993(1): 29-38.
43崔琼瑶,齐从谦.基于参数化技术的自顶向下设计及其应用.同济大学学报, 2002(9).
44刘辉,项昌乐,郑慕侨.模块化建模方法及其在车辆传动系中的应用.计算机仿真, 2002, 19(3): 61-67.
45 Kuo T C, Huang S H, Zhang H C. Design for manufacture and design for‘X’: concepts,applications, and Perspectives. Compute and Industrial Engineering. 2001, 41: 241-260.
46周世权,田文峰.机械制造工艺基础.武汉:华中科技大学出版社,2005.
47严蔚敏,吴伟民.数据结构(C语言版).北京:清华大学出版社, 1997.
48刘芳,王玲.基于动态规划思想求解关键路径的算法[J].计算机应用, 2006, 26(6): 1440-1442.
49刘豫,孙秦.大型结构动力特性的Lanczos数值计算方法及程序设计.科学技术与工程, 2008, 8(4).
50周宁. ANSYS机械工程应用实例.北京:中国水利水电出版社, 2006.
51丁历伟. CA4D32柴油机机体有限元动力分析.大连海事大学硕士毕业论文, 2007.
52 P.Rollet-Miet, D.Laurence, J.Ferziger. LES and RANS of turbulent flow in tube bundles. International Journal of Heat and Fluid Flow. 1999, 20(3): 241-254.
53 J.O.Hinze. Turbulent. McGraw-Hill, New York, 1975.
54 B.E.Launder, D.B.Spalding. Lectures in Mathematical Models of Turbulence. Academic Press, London, 1972.
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