• CN:11-2187/TH
  • ISSN:0577-6686

机械工程学报 ›› 2020, Vol. 56 ›› Issue (24): 61-71.doi: 10.3901/JME.2020.24.061

• 材料科学与工程 • 上一篇    下一篇

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基于SPH的平面曲线铝合金薄板滚压成形数值仿真与试验研究

李建军, 朱文峰   

  1. 同济大学机械与能源工程学院 上海 201804
  • 收稿日期:2020-03-02 修回日期:2020-08-25 出版日期:2020-12-20 发布日期:2021-02-05
  • 通讯作者: 朱文峰(通信作者),男,1976年出生,博士,教授,博士研究生导师。主要研究方向为车身数字化设计与制造。E-mail:zhuwenfeng@tongji.edu.cn
  • 作者简介:李建军,男,1984年出生,博士研究生。主要研究方向为胶粘异质薄板连接。E-mail:lijianjun@tongji.edu.cn
  • 基金资助:
    国家自然科学基金资助项目(51975416,51275359)。

Numerical Simulation and Experiment of Roller Hemming-compression with Flat Surface-curved Edge Aluminum Alloy Sheet Based on SPH

LI Jianjun, ZHU Wenfeng   

  1. School of Mechanical Engineering, Tongji University, Shanghai 201804
  • Received:2020-03-02 Revised:2020-08-25 Online:2020-12-20 Published:2021-02-05

摘要: 滚边压合是实现车身门盖件内外板高质量连接的装配工艺,其成形机理及质量预测一直是关注的重点。为定量揭示胶黏剂对轻质薄板成形的影响机理,引入光滑粒子法(Smoothed particle hydrodynamics,SPH)模拟胶黏剂,建立能满足工程实际的预测模型,并与传统欧拉法(Euler)进行了对比,验证了方法的可行性。以典型曲线轮廓结构为研究对象,采用有限元法(Finite element method,FEM)模拟铝合金薄板,建立SPH-FEM耦合的数值模型,对含胶滚压过程进行仿真,并通过试验进行了验证。然后,采用响应面法建立了胶层黏度、挤压速度和胶层厚度参数对成形质量交互影响的数学模型。研究表明,与无胶层相对比,有胶层的外板缩进值和最大塑性变形降低。胶层厚度对成形质量的影响显著,胶层黏度次之,滚压速度相对较小。基于SPH的建模方法解决了含胶滚压成形难以量化的问题,为工艺优化和提升制造精度提供了重要的理论依据。

关键词: 滚压成形, SPH-FEM耦合, 铝合金薄板, 胶黏剂

Abstract: Roller hemming-compression is an assembly process to realize high quality connection between inner and outer panels of auto-body, and its forming mechanism and quality prediction have always been the research focus. In order to quantitatively reveal the effect mechanism, the smoothed particle hydrodynamics(SPH) is introduced to simulate the adhesive, and a simulation prediction model is established, in line with the engineering. The feasibility is verified by comparing with the traditional Euler method. The finite element method(FEM) is used to simulate the aluminum alloy sheet with the typical flat surface-curved edge., and the SPH-FEM coupled numerical model is established. The process is simulated and analyzed, and verified by experiments. Then, the mathematical model of the interaction effect of adhesive viscosity, squeeze speed and adhesive thickness on forming quality is established by response surface method. Results show that the roll-in and maximum elastic-plastic deformation with adhesive decrease relatively, compared with the model without adhesive. The influence of the thickness of the adhesive on the forming quality is significant, followed by the viscosity of the adhesive, and the squeezing speed is not significant. The modeling method based on SPH solves the difficult quantification problem of forming with adhesive, and provides a important theoretical basis for process optimization and improvement of manufacturing accuracy.

Key words: roller-hemming forming, SPH-FEM coupled, aluminum alloy sheet, adhesive

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