研制及轻量化材料自冲铆接工艺开发

上海交通大学硕士学位论文自冲铆接设备研制及轻量化材料自冲铆接工艺开发姓名：楼铭申请学位级别：硕士专业：车辆工程指导教师：郭永进20090201IIICAbstractIIDEVELOPINGOFEQUIPMENTANDPROCESSOFSELF-PIERCINGRIVETINGFORLIGHTWEIGHTMATERIALSABSTRACTToday,thetrendoflightweightinautomotiveindustryhasbecomeinevitable,andextensiveuseofaluminumalloy,highstrengthsteelortheotheradvancedlightweightmaterialsisoneoftheimportantmeansthatcansolvethisproblemwell.Traditionalconnectiveprocessesfacewithenormousdifficultiesinconnectingthosematerials,butresearchhasshownthatself-piercingrivetingmethodisanewprocessthatcanjointhosematerialseffectively.Firstly,selectedtheappropriatepowersystemofself-piercingriveting,andbasedonthatpowersystemaC-framewasdesignedandcheckedforitsstiffnessbymeansofFEA,theresultshowedthatthisC-framewasinlinewiththerequirements,thenaccordingtothecharacteristicsoftheself-piercingrivetingprocessandthepurposeoftheexperiment,thewholerivetingstructurehadbeendesignedandmanufacturedwhichlaidasolidfoundationforthenextexperiments.Secondly,inducedtheconceptofdie-rivetvolumeratioandmadeAbstractIIIdetailedexperimentalprogramtodeveloptheinfluenceofdie-rivetvolumeratioontheformingpropertyandquasi-staticstrengthofthejointsofAl-AlandSt-Al,resultsshowedthatunderacertainscopetheincreasingofdie-rivetvolumeratiowasconductivetoimprovingtheformingqualityofthejoints.Finally,basedontheequipmentasetofself-piercingrivetingmonitoringsystemwasdevelopedwhichincludedthedisplacementsensor,thepressuresensor,thedisplayanddataextractionsystemoftheforce-displacementcurve.Andthenusingthismonitoringsystemtoanalyzetheformingmechanismofthejoints.Theexperimentsshowedthatthelargestrivetingforcewouldbelowerwhiledie-rivetvolumeratioincreased.KEYWORDSlightweight,self-piercingriveting,C-framedie-rivetvolumeratioquasi-staticstrength3535351[1]10%3.8%8%CO4.5%5%7%6%[2][3]1-1Figure1-1LightweightTrendofVehicle2[4][5][6,7]3[8](1)[9~11]1-2(a)(b)(c)(d)Figure1-2ProcessofClinching1.2.3.4.5.342514(2)[12~15]6mm10mm1-3(a)(b)(c)(d)(e)Figure1-3ProcessofSelf-piercingRiveting(a)(b)-(e)(b)(c)5(d)(e)A.B.12%C.D.E.14[16](1)A.B.C.D.(2)(3)6(4)(5)(6)(7)(8)(9)(10)(11)80[17~19]1985HENROBEMHARTBOLLHOFF(1)(2)(3)(4)CE(5)HENROBC1-42001HENROB7Figure1-4Self-piercingRivetingSystemofHENROB1993A8X350XJ81-53000UK14008VOLVO-FH1230%[20]Figure1-5JaguarXJ8withRivetedAluminumBodyinWhite(1)R.PorcaroA.G.HanssenAA606004590[21]LivanFratiniVincenzoFortunatoRuisi[22]Khezri480HV555HVDP600480HV[23]L.HanK.W.Young9HSLA350NG5754HSLA350[24]C.G.PickinK.W.Young[25]L.HanA.Chrysanthou[26]Y.XuDOE[27]Dae-WookKimJunXu[28]X.SunM.A.Khaleel[29]Y.AbeT.Kato[30](2)34606310[31][32][33][34](1)DT—DestructiveTesting11(2)NDT—Non-destructiveTesting1-6HENROBHenrobsRivMonTM[35]BOLLHOFFRIVSETORBITFORMWatchDawgFigure1-6RivMonQualityMonitoringSystemofHENROBCo.12(1)SMARTC(2)(3)13SMART[36]2-1Figure2-1Pneudraulic_cylinder(1)(2)2bar-6bar2kN-2000kN(3)(4)14(5)(6)SMART2-2(a)(b)(c)(d)A.B.C.X.Figure2-2WorkingPrincipleofPneudraulic_cylinder(a)(b)-(d)(b)A(c)BC(d)15ABCCCCCCC2-3Figure2-3FlowChartofFEA16CmmCC45Figure2-4DesignDrawingofC-frameCUnigraphicsNX4UnigraphicsNX4UGNX4EDSNXCAD/CAM/CAEUnigraphicsGE17DensoBEAerospace3MDECPhilipsUnigraphicsUGNX4CUGNX42-5Figure2-5UGAssemblyofC-frameCUGHypermesh8.018HypermeshAltairCAECAECAEHypermeshCAE80%CAD(1)C452.1e5MPa0.37.9e-9t/mm3(2)C(3)Crbe2rbe2rbe2C(4)C(5)Crbe3Hypermeshrbe3rbe3100kN100kNC19Figure2-6FEModelofC-frameCNastranop2AltairHyperviewCXY(1)CX2-7CXCX0.3791mm755mm0.05%20Figure2-7X-DirectionalDeformationofC-frame2-8XX0.0452mm6-8mmXFigure2-8X-DirectionalDisplacementofPunch(2)CY2-9CYCY0.3003mmC21C1524.5mm0.02%Figure2-9Y-DirectionalDeformationofC-frame2-10YY0.2394mm50mm0.479%YFigure2-10Y-DirectionalDisplacementofPunch22(1)2-11Figure2-11TheFirstMechanismofSelf-piercingRiveting1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.23115C3234365679812131415345679276257625(2)2-1224Figure2-12TheSecondMechanismofSelf-piercingRiveting1.2.3.4.5.6.7.8.9.10.11.12.13.14.52C125625(1)[37][38]6AA6061-T6DP7802-3mm1-1.8mm2-1Table2-1PlatesforExperimentmmMPaMPa%2AA6061-T63286.5333.013.4DP7801.4555.4754.919.2(2)4[39]2-13(a)(b)(c)(d)Figure2-13Half-hollowRivet26[32][40]7mm2-14CADAUTOCAD20077mmCADVR=110.16mm3Figure2-14SectionofPanHeadHalf-hollowRivet[41][42]D17mmD12-1527Figure2-15DieProfilerVDVR2-22-15DHTable2-2DieParametersD/mmH/mmVD/mm³r=VD/VRD14.42.0110.571.00D24.32.0104.830.95D34.52.0116.421.06D44.62.0122.411.11D54.41.9106.080.96D64.42.1114.911.04D74.42.2119.091.0828CC29(1)(2)6bar(3)16qfp×=qbarfkgf5bar5kN(4)ON(5)(6)(7)(8)(5)~(7)[37][38]Henrob7mm302-17mmD13-1Table3-1TestingSelf-piercingRivetingProgram12mmAA6061-T6+2mmAA6061-T622mmAA6061-T6+3mmAA6061-T632mmAA6061-T6+1.4mmDP78041.4mmDP780+2mmAA6061-T653mmAA6061-T6+1.4mmDP78061.4mmDP780+3mmAA6061-T612mmAA6061-T6+2mmAA6061-T653-126(a)2(b)3CAB31(c)4(d)5(e)6Figure3-1SectionofTestingSelf-piercingRivetingSamples3-1(a)7mm2mmAA6061-T63mmAA6061-T63-1(b)7mm2mmAA6061-T61.4mmDP7803ABC7mm3-1(c)41.4mmDP780+2mmAA6061-T63ABCBACA323-1(d)53mmAA6061-T6+1.4mmDP7803-1(e)61.4mmDP780+3mmAA6061-T6130mm38mm[24]3-2(a)(b)Figure3-2ExperimentalSamples33D1(1)AA6061-T62mm+3mm7mmVR=110.16mmA.T