薄板结构成形与耐撞性优化设计关键技术研究
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摘要
薄板结构成形与耐撞性设计一直是制约汽车产品开发速度与品质的两项关键技术。传统的薄板结构成形与耐撞性设计主要依靠工程技术人员的经验进行“试错”来提高产品设计的质量。这种试错方法不仅耗时长、费用高,还往往难以保证产品设计的品质。随着有限元方法的发展和成熟,CAE技术已经广泛用于薄板结构的成形与耐撞性设计。尽管有限元分析方法促进了车身类薄板结构件的成形性和耐撞性研究的进步,一定程度上避免了设计的盲目性、减少了设计成本以及缩短了车身结构的开发周期,但是有限元方法本身仅作为一种分析手段,其主要功能只是对给定设计进行评价和校核。为了充分发挥CAE技术的潜能,将CAE技术与优化算法相结合来提高薄板结构的成形性和耐撞性已成为国际上许多学者研究的前沿课题。本文主要围绕如何提高薄板结构的成形性与耐撞性优化设计的效率,精度以及结果的稳健性等几个关键技术展开研究。
主要研究内容如下：
(1)提出了一种能量化冲压件起皱缺陷和拉裂缺陷的指数加权评价准则,该准则具有对不同的潜在失效单元赋予不同权重的优点,且权重随着拉裂、起皱的严重程度成指数函数增长。和现有的其它评价准则相比,将该准则作为板料成形优化设计的目标函数具有更强的针对性,优化结果能显著的提高板料的成形质量。在板料成形多目标优化研究方面,本文提出了基于径向基函数的板料成形多目标优化方法。研究表明基于薄板样条函数(Thin-plate spline)的径向基函数模型非常适合作为板料成形仿真的代理模型。在多目标优化迭代过程中,该方法调用的是代理模型而非有限元模型,因此,提出的方法具有非常高的效率。同时,该方法能解决拉裂和起皱缺陷同时存在且相互冲突的问题。在薄壁结构耐撞性研究方面,提出了一种新型的功能梯度泡沫填充薄壁结构。该新型泡沫填充结构的泡沫密度沿着长度方向成幂指数连续变化。数值算例表明,幂指数m对该结构的耐撞性有重要的影响。在此基础上,对该结构的幂指数m进行了优化设计。优化结果表明该结构在能量吸收、变形稳定性和最大峰值碰撞力方面比同质量的均匀泡沫填充薄壁结构具有更佳的耐撞性,是一种潜在的性能卓越的吸能结构。
(2)提出了一种薄板结构成形与耐撞性序列代理模型优化设计方法,并对逐步序列的增加样本点数量和逐步序列减少设计空间这两种序列策略进行了研究。研究表明在样本点数量相同的情况下,无论是基于哪一种序列策略的序列代理模型优化设计方法的优化结果的精度均比传统的基于代理模型的优化设计方法的优化结果的的精度高。同时,提出的方法还具有对初始样本的数量与分布的依赖性相对较弱等优点。DP800高强度钢材料参数的反求优化设计和拉延筋几何参数的优化设计结果表明了该方法具有非常高的精度和效率。在此基础上,将单目标序列优化方法拓展到了多目标优化设计领域,提出了多目标序列代理模型优化方法。并开展了拉延筋几何参数多目标序列代理模型优化设计和汽车结构耐撞性多目标序列代理模型优化设计方法研究。
(3)为了充分发挥高精度模型计算精度高和低精度模型耗时少的优点,提出了一种基于代理模型的板料成形变复杂度优化设计方法。该方法的核心是首先在高精度模型和低精度模型问建立一个补偿模型,然后对低精度模型进行补偿,补偿后的低精度模型的仿真结果的精度将得到大大的提高,在优化过程中可以代替高精度模型的结果。采用提出的方法对某汽车内板的拉延筋进行了优化设计研究,结果表明提出的方法的优化效率尽管低于基于一步法的优化效率,但优化结果的精度却得到了显著的提高；与传统的基于代理模型的优化方法相比,在相同的求解效率下,提出的方法的求解精度更高。
(4)由于薄壁结构成形与耐撞性变复杂度优化在迭代过程中调用的低精度模型仍为有限元模型,这些模型在仿真过程中存在数值噪声,目标函数易陷入因数值噪声引起的局部峰值中,最终的优化结果难以直接用于指导实际的设计。薄壁结构成形与耐撞性数值模拟中,单元计算或接触计算常常产生问题,导致在优化过程中因单次仿真的失效而使整个优化过程无法进行。为了解决上述问题,提出了两步变复杂度优化方法,并开展了板料成形和蜂窝结构耐撞性的二步变复杂度优化方法研究。研究结果表明该方法具有较高的效率和精度,特别适合求解像板料成形和汽车碰撞这类复杂的非线性工程优化问题。
(5)进行了汽车构件耐撞性可靠性优化设计、薄壁构件耐撞性6sigma单目标稳健优化设计和薄板冲压成形6sigma单目标稳健优化设计研究。在此基础上,提出了基于双响应面模型的6sigma多目标稳健优化设计方法。该方法不仅考虑了噪声因素的波动对产品性能的影响,同时也解决了多个质量特性之间互相冲突的问题。应用该方法开展了汽车结构耐撞性和板料成形多目标稳健优化研究。研究结果表明提出的方法能显著的提高设计结果的稳健性。
Forming and crashworthiness design of sheet structures are two key technologies to restrict the development rapidity and quality of automobile product. Traditional forming and crashworthiness design of sheet structures mainly depend on experience available by incorporating with a trial and error procedure to improve the product design quality. As a result, the design method requires a long design cycle and significant cost, whearas this by no means guarantees the quality of product. As the development and maturity of finite element method, CAE technology has been widely applied in the forming and crashworthiness design of sheet structrues. Although the finite element analysis promotes the progress of vehicle body parts in sheet metal forming and crashworthiness, avoids the blindness, reduces the design cost and shortens the development cycle to considerable extent, the finite element analysis is only a tool to evaluate and verify the product design. In order to take up the protential of CAE technology, it has been studied by a lot of researcher and become an international hot issue that integrating the CAE technology and optimization algorithm togother to improve the formability and crashworthiness of sheet structure. The paper mainly focuses on how to improve the optimization design efficiency, accuracy and robustness in the forming and crashworthiness design of sheet structures.
The detailed content is as follows:
(1) The paper presents an exponential weighted evaluation criterion which can evaluate the defects of wrinkle and crack. The criterion has the advantage of giving different protentional failure elements to different weighted values, and these values increase with the severity of crack and wrinkling in an expontential function. Compared with the other existing criteria, the criterion presented takes as objective function, which is more targeted and can significantly improve the formability of sheet metal forming. In the multiobjecvtive optimization of sheet metal forming, the paper presents a multiobjective optimization algorithm of sheet metal forming based radial basis function. The research result shows that the radial basis function based thin-plate spline is very suitable as surrogate model of sheet metal forming. The method proposed has very high efficiency due to calling surrogate model not the finite element model in the multiobjective optimization iterative process. In the crashworthiness research of thin walled structures, the paper presents a novel functionally graded foam-filled thin walled structure. In which, the foam density varies throughout the depth in a certain expotential function. Numerical simulations show that gradient exponential parameter m has significant effect on system crashworthiness. On the basis, the parameter m is optimized. The result shows that the columns filled by graded foam provide a better crashworhtinss performance than the uniform counterpart in the energy absorption, deformation stability, peak force. Hence, the functionally graded foam-filled thin walled structure is a protentional excellent energy absorption structure.
(2) The paper presents a sequential surrogate model optimization design method of forming and crashworthiness of sheet structures. These two strategies of gradually sequentially increasing the number of the samples and decreasing the design space have been studied. The results show that the accuracy of the sequential surrogate model method based on no matter what kind of sequential strategy is higher than the accuracy of traditional surrogate method method. The method prestened has the advantage of relative weak dependence on the number of initial samples and distribution of initial samples. The optimal results of the DP800high strength steel material parameter identification and the drawbead geometrical parameter design show the sequential approximation method has very high accuracy and efficience. Baed on this, a multiobjective sequential method based metamodel is presented to extend the single objective sequential method to multiobjective optimization design. The research on drawbead geometrical parameter multiobjective sequential surrogate model optimization design method and vehicle structure crashworthiness multiobjective sequential surrogate model optimization design method are carried out.
(3) In order to take full of the advantages of both the high fidelity model and low fidelity model, we present a variable fidelity model based metamodel. The key of the method presented is to construct a compensate model between the high fidelity model and low fidelity model firstly, and then compensate the low fidelity model. The precision of the low fidelity model compensated will be improved siginificantly. Therefore, the result of the low fidelity model compensated can be used to replace the result of the high fidelity model in the optimization process. The drawbead of some vehicle inner panel is studied using the method proposed. The result shows though the efficiency of the method proposed is lower than the efficiency of the one step method, the accuracy of the optimal design is improved significantly. Compared with the traditional surrogate model method, the accuracy of the method proposed is higher under the same solution efficiency.
(4) The variable fidelity algorithm of forming and crashworthiness of sheet structure call the low fidelity models which are often finite element models in the optimization iterative process. The objective function value often falls into the local optimal result due to some numerical noises in the finite element analysis. So, the optimal is difficult to guide the real design. On the other hand, in the simulation of forming and crashworthiness of steel structure, the element deformation behaviors and frictional conatact involved in the simulation model sometimes result in unstable simulation analysis. As such, the collapse of a single finite element simulation may lead to whole optimization procedure being terminated prematurely. In order to address the issue mentioned above, the paper develops a two stage multifidility optimization algorithm. The optimal results of the two stage multifidelity optimization based on metamodel for honeycomb structure crashworthiness design and sheet metal forming design show that the method presented has high efficiency and accuracy, especially suitable solving complicated nonlinear engineering problems such sheet metal forming as vehicle crashworthiness.
(5) The research on the reliability optimization design of the crashworthiness for vehicle part, the single objective robust optimization design based on6sigma of sheet metal forming and crashworthiness of thin-walled structures are carried out. On the basis, the paper presents a6sigma multiobjective robust optimization algorithm based on dual response method. The method proposed not only takes the perturbations of noise factors into account, but also solves the problem of some quality characteristics conflicting with each other. The multiobjective roubst optimization method is applied to the crashworthiness of vehicle structures and sheet metal forming optimization design. The study shows that the method proposed can significantly improve the robustness of the design result.
主要研究内容如下：
(1)提出了一种能量化冲压件起皱缺陷和拉裂缺陷的指数加权评价准则,该准则具有对不同的潜在失效单元赋予不同权重的优点,且权重随着拉裂、起皱的严重程度成指数函数增长。和现有的其它评价准则相比,将该准则作为板料成形优化设计的目标函数具有更强的针对性,优化结果能显著的提高板料的成形质量。在板料成形多目标优化研究方面,本文提出了基于径向基函数的板料成形多目标优化方法。研究表明基于薄板样条函数(Thin-plate spline)的径向基函数模型非常适合作为板料成形仿真的代理模型。在多目标优化迭代过程中,该方法调用的是代理模型而非有限元模型,因此,提出的方法具有非常高的效率。同时,该方法能解决拉裂和起皱缺陷同时存在且相互冲突的问题。在薄壁结构耐撞性研究方面,提出了一种新型的功能梯度泡沫填充薄壁结构。该新型泡沫填充结构的泡沫密度沿着长度方向成幂指数连续变化。数值算例表明,幂指数m对该结构的耐撞性有重要的影响。在此基础上,对该结构的幂指数m进行了优化设计。优化结果表明该结构在能量吸收、变形稳定性和最大峰值碰撞力方面比同质量的均匀泡沫填充薄壁结构具有更佳的耐撞性,是一种潜在的性能卓越的吸能结构。
(2)提出了一种薄板结构成形与耐撞性序列代理模型优化设计方法,并对逐步序列的增加样本点数量和逐步序列减少设计空间这两种序列策略进行了研究。研究表明在样本点数量相同的情况下,无论是基于哪一种序列策略的序列代理模型优化设计方法的优化结果的精度均比传统的基于代理模型的优化设计方法的优化结果的的精度高。同时,提出的方法还具有对初始样本的数量与分布的依赖性相对较弱等优点。DP800高强度钢材料参数的反求优化设计和拉延筋几何参数的优化设计结果表明了该方法具有非常高的精度和效率。在此基础上,将单目标序列优化方法拓展到了多目标优化设计领域,提出了多目标序列代理模型优化方法。并开展了拉延筋几何参数多目标序列代理模型优化设计和汽车结构耐撞性多目标序列代理模型优化设计方法研究。
(3)为了充分发挥高精度模型计算精度高和低精度模型耗时少的优点,提出了一种基于代理模型的板料成形变复杂度优化设计方法。该方法的核心是首先在高精度模型和低精度模型问建立一个补偿模型,然后对低精度模型进行补偿,补偿后的低精度模型的仿真结果的精度将得到大大的提高,在优化过程中可以代替高精度模型的结果。采用提出的方法对某汽车内板的拉延筋进行了优化设计研究,结果表明提出的方法的优化效率尽管低于基于一步法的优化效率,但优化结果的精度却得到了显著的提高；与传统的基于代理模型的优化方法相比,在相同的求解效率下,提出的方法的求解精度更高。
(4)由于薄壁结构成形与耐撞性变复杂度优化在迭代过程中调用的低精度模型仍为有限元模型,这些模型在仿真过程中存在数值噪声,目标函数易陷入因数值噪声引起的局部峰值中,最终的优化结果难以直接用于指导实际的设计。薄壁结构成形与耐撞性数值模拟中,单元计算或接触计算常常产生问题,导致在优化过程中因单次仿真的失效而使整个优化过程无法进行。为了解决上述问题,提出了两步变复杂度优化方法,并开展了板料成形和蜂窝结构耐撞性的二步变复杂度优化方法研究。研究结果表明该方法具有较高的效率和精度,特别适合求解像板料成形和汽车碰撞这类复杂的非线性工程优化问题。
(5)进行了汽车构件耐撞性可靠性优化设计、薄壁构件耐撞性6sigma单目标稳健优化设计和薄板冲压成形6sigma单目标稳健优化设计研究。在此基础上,提出了基于双响应面模型的6sigma多目标稳健优化设计方法。该方法不仅考虑了噪声因素的波动对产品性能的影响,同时也解决了多个质量特性之间互相冲突的问题。应用该方法开展了汽车结构耐撞性和板料成形多目标稳健优化研究。研究结果表明提出的方法能显著的提高设计结果的稳健性。
Forming and crashworthiness design of sheet structures are two key technologies to restrict the development rapidity and quality of automobile product. Traditional forming and crashworthiness design of sheet structures mainly depend on experience available by incorporating with a trial and error procedure to improve the product design quality. As a result, the design method requires a long design cycle and significant cost, whearas this by no means guarantees the quality of product. As the development and maturity of finite element method, CAE technology has been widely applied in the forming and crashworthiness design of sheet structrues. Although the finite element analysis promotes the progress of vehicle body parts in sheet metal forming and crashworthiness, avoids the blindness, reduces the design cost and shortens the development cycle to considerable extent, the finite element analysis is only a tool to evaluate and verify the product design. In order to take up the protential of CAE technology, it has been studied by a lot of researcher and become an international hot issue that integrating the CAE technology and optimization algorithm togother to improve the formability and crashworthiness of sheet structure. The paper mainly focuses on how to improve the optimization design efficiency, accuracy and robustness in the forming and crashworthiness design of sheet structures.
The detailed content is as follows:
(1) The paper presents an exponential weighted evaluation criterion which can evaluate the defects of wrinkle and crack. The criterion has the advantage of giving different protentional failure elements to different weighted values, and these values increase with the severity of crack and wrinkling in an expontential function. Compared with the other existing criteria, the criterion presented takes as objective function, which is more targeted and can significantly improve the formability of sheet metal forming. In the multiobjecvtive optimization of sheet metal forming, the paper presents a multiobjective optimization algorithm of sheet metal forming based radial basis function. The research result shows that the radial basis function based thin-plate spline is very suitable as surrogate model of sheet metal forming. The method proposed has very high efficiency due to calling surrogate model not the finite element model in the multiobjective optimization iterative process. In the crashworthiness research of thin walled structures, the paper presents a novel functionally graded foam-filled thin walled structure. In which, the foam density varies throughout the depth in a certain expotential function. Numerical simulations show that gradient exponential parameter m has significant effect on system crashworthiness. On the basis, the parameter m is optimized. The result shows that the columns filled by graded foam provide a better crashworhtinss performance than the uniform counterpart in the energy absorption, deformation stability, peak force. Hence, the functionally graded foam-filled thin walled structure is a protentional excellent energy absorption structure.
(2) The paper presents a sequential surrogate model optimization design method of forming and crashworthiness of sheet structures. These two strategies of gradually sequentially increasing the number of the samples and decreasing the design space have been studied. The results show that the accuracy of the sequential surrogate model method based on no matter what kind of sequential strategy is higher than the accuracy of traditional surrogate method method. The method prestened has the advantage of relative weak dependence on the number of initial samples and distribution of initial samples. The optimal results of the DP800high strength steel material parameter identification and the drawbead geometrical parameter design show the sequential approximation method has very high accuracy and efficience. Baed on this, a multiobjective sequential method based metamodel is presented to extend the single objective sequential method to multiobjective optimization design. The research on drawbead geometrical parameter multiobjective sequential surrogate model optimization design method and vehicle structure crashworthiness multiobjective sequential surrogate model optimization design method are carried out.
(3) In order to take full of the advantages of both the high fidelity model and low fidelity model, we present a variable fidelity model based metamodel. The key of the method presented is to construct a compensate model between the high fidelity model and low fidelity model firstly, and then compensate the low fidelity model. The precision of the low fidelity model compensated will be improved siginificantly. Therefore, the result of the low fidelity model compensated can be used to replace the result of the high fidelity model in the optimization process. The drawbead of some vehicle inner panel is studied using the method proposed. The result shows though the efficiency of the method proposed is lower than the efficiency of the one step method, the accuracy of the optimal design is improved significantly. Compared with the traditional surrogate model method, the accuracy of the method proposed is higher under the same solution efficiency.
(4) The variable fidelity algorithm of forming and crashworthiness of sheet structure call the low fidelity models which are often finite element models in the optimization iterative process. The objective function value often falls into the local optimal result due to some numerical noises in the finite element analysis. So, the optimal is difficult to guide the real design. On the other hand, in the simulation of forming and crashworthiness of steel structure, the element deformation behaviors and frictional conatact involved in the simulation model sometimes result in unstable simulation analysis. As such, the collapse of a single finite element simulation may lead to whole optimization procedure being terminated prematurely. In order to address the issue mentioned above, the paper develops a two stage multifidility optimization algorithm. The optimal results of the two stage multifidelity optimization based on metamodel for honeycomb structure crashworthiness design and sheet metal forming design show that the method presented has high efficiency and accuracy, especially suitable solving complicated nonlinear engineering problems such sheet metal forming as vehicle crashworthiness.
(5) The research on the reliability optimization design of the crashworthiness for vehicle part, the single objective robust optimization design based on6sigma of sheet metal forming and crashworthiness of thin-walled structures are carried out. On the basis, the paper presents a6sigma multiobjective robust optimization algorithm based on dual response method. The method proposed not only takes the perturbations of noise factors into account, but also solves the problem of some quality characteristics conflicting with each other. The multiobjective roubst optimization method is applied to the crashworthiness of vehicle structures and sheet metal forming optimization design. The study shows that the method proposed can significantly improve the robustness of the design result.
引文
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