汽车典型覆盖件曲面重构及成形过程缺陷分析

上海交通大学硕士学位论文汽车典型覆盖件曲面重构及成形过程缺陷分析姓名：黄平华申请学位级别：硕士专业：材料学指导教师：何丹农20070201ICAD/CAE/CAMCADIMAGEWARECADDYNAFORMBalartBelytschko-TsayIIABSTRACTIIISURFACERECONSTRUCTIONOFTHETYPICALAUTOPANELANDTHEANALYSISOFDEFECTINFORMINGPROCESSABSTRACTWiththedrasticallycompetitionbetweentheglobalcarmaker,theauto-industryofourcountryfacesseriouschallenge.Itisurgentforourcountryhowtoabsorbtheadvancedtechnologyinbaseofintroducingaseriesofstampingmouldstoestablishkeytechnologywithindependentknowledgepropertyrightandthenbreakawaythedependenceofforeignenterprisesandraisetheinnovativeability.Thedesignandmanufacturingtimeandqualityofpaneldieshavedirecteffectonthedevelopmentperiodofnewcars,theirqualityandcompetitivecapability.ThispaperfocusedoncomprehensivestudyofsurfaceCADReverseEngineering(RE)modelingandFiniteElementAnalysis(FEA)forformingprocessofautomobilebacktrunkinnerpanelinordertoshortentheperiodofresearchanddevelopmentformoderncar,improvethequalityofbodycoverpanelandreducethecost.TocreateFEAmodelforcoverpanelformingprocess,firstly,reducingandnoiseeliminatingprocesswereappliedintheoriginalcloudofcoverpanelwiththeIMAGEWAREsoftware.Then,theCADmodelofthesurfacewascreatedthroughreverseandobversemethodbasedontheanalysisofcharacterofthecoverpanel.Thirdly,theCADmodelwasimportedintotheDYNAFORMsoftware.Barlat3-parameteryieldmodelandBelytschko-TsayshellelementwereusedforFEsimulationaccordingtocharacterofcoverpanelformingprocessandmaterials.TheFEAsimulationsystemofstampingprocesswasbuiltandthesimulationresultwasconsistentwithpractice.Theproducingmechanismandcorrespondingcountermeasureofthedefectsuchasbreakandwrinklewererevealed.TheoptimizedparametersforcoverpanelformingprocesswereobtainedthroughFEsimulation.ABSTRACTIVInconclusion,theresultspresentedinthepaperarevaluableforpracticeofcoverpanelformingprocessandothersimilarparts.IncorporatingreverseengineeringmethodintoFEsimulationofautomobilecoverpanelformingprocessisconducivetoemployinformationtechnologyinauto-industryandhasimportantscientificandpracticalsignificance.Keywords:auto-bodycoverpanel,reverseengineering,finiteelementnumericalsimulation11.12/3[1]801.3[2]30CAD/CAE/CAM[3]CAD/CAE/CAMCAECADCAECAD/CAM2CAD/CAE/CAM1.2[4](autobodypanels)1-11-1Fig.1-1PanelsAnalysisofAutomobile31.2.1123451.2.214(2)1.3[5](ReverseEngineeringRE)2090CAD/CAM1.3.11CMM23CADCADCAD4CADCADCAD1-251-2Fig.1-2FlowchartofRE1.3.2CAD(1)(CAD)CADCAD(2)CAD(3)CAECADPDMCAD/CAECADCAMRP6(4)CAD/CAMCAD/CAMCADCAD(5)(6)(7)(8)RPM1.4(CAE)1.4.150finiteelementanalyzeClough[6]19601970HibbitMarcalRice[7]Lagrangiantotallagrangianformulation,T.L.McMeekingRice[8]1974LagrangianupdatedlagrangianformulationU.L.1978N.M.WangBudiansky[9]T.L.1982Lee7FordS.C.Tang[10]N.M.Wang1981Tang1.4.2[12]ETADYNAFORMLSTCLS-DYNA3DHKSABAQUSESIPAM-Stamp1-31-31DFM(DesignForManufacturing)CAD3CADFEACAD458123123451-3Fig.1-3Flowchartofdesignandmanufactureofthedie1-31.4.380[13][14]Lagrange[15][16][17]92003[18]DYNAFORMPAM-STAMP[19]1.512CAD310UG/IMAGEWARECAD112.1[20]2.12-1Fig.2-1Sortsofdatemeasuring2.1.1[21](CoordinateMeasureMachine,CMM)2060CMMCTMRI12ASCII2.1.21[22]()2[23]()ShadowMoire133[24]2.22-22-2Fig.2-2Flowchartofdatepre-treatment2.2.1()14FaugerasHebert[25]1986QuaternionArun[26]1988SVD(SingularValueDecomposition)BeslMckay[27]1992IterativeClosestPointICPPQQ()P(Q)PQPQRTP=RP+T{}n21pppP⋅⋅⋅={}m21Qqqq⋅⋅⋅=Qp⊆(1)PPpi∈Qjq()jiqp,(2)RT()jiqp,()()211,∑=+−=niijTRpqnTRE2.1(3)RTPPTRpi+(4)(2-1)kkRkTkkkkTPRP+=+11+kPQ1+kR1+kTNλ()()λ≤−++kkkkTRETRE112.2.211523~4ie[]εip3ipie[]ε≥ie[]εiph2.2.3Martin[28]1996Chen1999STLSTLLee[29]2001[30]2004(Paraboloidfitting)22cybxyaxz++=162.2.4(PointDataSegmentation)CAD(Edge-Base)(Surface-Based)Yang[31]19992.3CADCAD[32]BezierNURBSBCAD/CAM172.3.1[33]:2.3.1.1Bezier()/BezierBezier()()iniinPuBuC∑==0,[]1,0∈u(2.2)iPnu()uBin,Bezier()()()()iniininiinuuiinnuuCuB−−−−=−=1!!!1,(2.3)nBeziern+1[0,1]Bezier1n+1nBezier:(1)Bezier()∑≡niinuB1,(),10,≤≤uBin10≤≤uni⋅⋅⋅=102.4u[0,l]u()uCiP()uBin,Bezier()uCiPBezier2Bezier183BeziernininiVniVniV+−++=−+111112.54BezierBezier()()()∑∑===minjnjmiwBuBwuS00,2.6BezierBezier2.3.1.2B-Spline/Bezier(cordon)(Riesenfeld)BezierBBernsteinBezierB-Spline()()inipnPuNuC∑==0,2.7iPp()uNpn,B-SplineB-Spline()=010,uNi{}{}11++∉∈iiiiuuuuuu()()()()()111,111,,+++−++++−−−+−−=ipipipiipipiipiuuuNuuuuuNuuuN[]pni+∈02.8B-SplineBezierB-SplineB-Spline()uNpn,0u191u2u...pnu+1++pn(0u1u...pnu+)BkBk+1(iu1+iu)k12...k-11−kCB2CB-SplineB-SplineBB-Spline1B-Splinek()uNpn,k-1Bezier2()uNpn,iPB-Spline3k45BBkBk-1BezierB-Spline(u)(u,v)B-Spline()()()∑∑===minjijqjpiPvNuNvuS00,,,2.92.3.1.3NURBS/BBNURBS(Non-UniformRationalB-Spline)kNURBS20()()()()∑∑∑=====niipiniipiniiipiPuRwuNPwuNuC0,0,0,2.10iP()uNpn,pB-Splineiwu()uRpi,B-Splineiw)/NURBSuuvNURBS()()()()()()∑∑∑∑∑∑========minjijqjpimrnsrsqsprminjijijqjpiPvuRwvNuNPwvNuNvuS00,,,00,,00,,,,2.11NURBS()()()()()∑∑===mrnsrsqsprijqjpiqjpiwvNuNwvNuNvuR00,,,,,,,,2.12NURBS123NURBSNURBS4NURBSNURBSBCADNURBSIGESS'T'EPNURBS212.3.2[34]1Bezier,B-SplineNURBSNURBSNURBSCADNURBS2BezierBezierUGPRO/ECADNURBSBezier(COONS)NURBS3NURBSNURBS2.3.3CAD/CAM/CA