Article(id=1208718300591296604, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1208718299400106845, articleNumber=null, orderNo=null, doi=10.19710/J.cnki.1003-8817.20230277, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1766110499761, onlineDateStr=2025-12-19, pubDate=1724083200000, pubDateStr=2024-08-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1766110499761, onlineIssueDateStr=2025-12-19, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1766110499761, creator=13701087609, updateTime=1766110499761, updator=13701087609, issue=Issue{id=1208718299400106845, tenantId=1146029695717560320, journalId=1189873562199433220, year='2024', volume='', issue='8', pageStart='1', pageEnd='72', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1766110499477, creator=13701087609, updateTime=1766110499477, updator=13701087609, preIssue=null, nextIssue=null, ext=null, issueFiles=null}, startPage=7, endPage=11, ext={EN=ArticleExt(id=1208718300792623197, articleId=1208718300591296604, tenantId=1146029695717560320, journalId=1189873562199433220, language=EN, title=Nonlinear Simulation Analysis of Gravity Deformation of Sheet Stampings for Body-in-White, columnId=null, journalTitle=Automobile Technology & Material, columnName=null, runingTitle=null, highlight=null, articleAbstract=

In order to analyze the influence of gravity deformation on the size pass rate of sheet stampings, Hypermesh and Abaqus were used to construct the nonlinear co-simulation model of gravity deformation of the sunroof cover plate and the tunnel welding assembly. The results show that different placement positions have different abilities to overcome gravity deformation, and the convex placement can improve the ability of parts to overcome gravity deformation. The simulation results verify the feasibility of nonlinear analysis method of gravity deformation to guide the measurement scheme design of sheet stampings of BIW.

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为分析自重变形对薄板冲压件尺寸检测合格率的影响,利用HyperMesh与Abaqus构建天窗顶盖外板和中通道焊接总成自重变形非线性联合仿真模型。结果表明,不同的摆放姿态克服自重变形的能力不同,凸放可以提高零件克服自重变形的能力,验证了自重变形非线性分析方法指导白车身薄板冲压件测量方案设计的可行性。

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刘永超(1992—),男,硕士学位,主要研究方向为车身尺寸匹配技术。

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刘永超(1992—),男,硕士学位,主要研究方向为车身尺寸匹配技术。

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刘永超(1992—),男,硕士学位,主要研究方向为车身尺寸匹配技术。

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仿真参数 数值
冲压件网格尺寸/mm 5
定位面网格尺寸/mm 3
重力加速度/mm·s-2 9 806
钢密度/t·mm-3 7.9×10-7
钢弹性模量/MPa 210 000
泊松比 0.3
摩擦因数 0.15
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仿真参数

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仿真参数 数值
冲压件网格尺寸/mm 5
定位面网格尺寸/mm 3
重力加速度/mm·s-2 9 806
钢密度/t·mm-3 7.9×10-7
钢弹性模量/MPa 210 000
泊松比 0.3
摩擦因数 0.15
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定位 方向 尺寸/mm X/mm Y/mm Z/mm
B XY Φ12 3 987.13 370.00 2 181.03
C X Φ12 3 987.13 -370.00 2 181.03
D1 X 8×12 2 043.62 427.00 2 199.00
D2 X 8×12 2 043.62 -427.00 2 199.00
E1 Y 5×12 2 246.00 562.6. 2 237.00
E2 Y 5×12 2 246.00 -562.6. 2 237.00
A1 Z 10×20 2 229.00 578.00 2 224.26
A2 Z 10×20 2 699.00 549.00 2 263.88
A3 Z 10×20 3 222.00 539.00 2 254.33
A4 Z 10×20 3 758.00 532.00 2 214.62
A5 Z 20×50 3 987.00 355.00 2 181.04
A6 Z 20×50 3 987.00 -355.00 2 181.04
A7 Z 10×20 3 758.00 -532.00 2 214.62
A8 Z 10×20 3 222.00 -539.00 2 254.33
A9 Z 10×20 2 699.00 -549.00 2 263.88
A10 Z 10×20 2 229.00 -578.00 2 224.26
A11 Z 10×20 2 018.00 -365.00 2 189.05
A12 Z 10×20 1 981.00 0.00 2 198.91
A13 Z 10×20 2 018.00 365.00 2 189.05
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天窗顶盖外板定位基准信息

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定位 方向 尺寸/mm X/mm Y/mm Z/mm
B XY Φ12 3 987.13 370.00 2 181.03
C X Φ12 3 987.13 -370.00 2 181.03
D1 X 8×12 2 043.62 427.00 2 199.00
D2 X 8×12 2 043.62 -427.00 2 199.00
E1 Y 5×12 2 246.00 562.6. 2 237.00
E2 Y 5×12 2 246.00 -562.6. 2 237.00
A1 Z 10×20 2 229.00 578.00 2 224.26
A2 Z 10×20 2 699.00 549.00 2 263.88
A3 Z 10×20 3 222.00 539.00 2 254.33
A4 Z 10×20 3 758.00 532.00 2 214.62
A5 Z 20×50 3 987.00 355.00 2 181.04
A6 Z 20×50 3 987.00 -355.00 2 181.04
A7 Z 10×20 3 758.00 -532.00 2 214.62
A8 Z 10×20 3 222.00 -539.00 2 254.33
A9 Z 10×20 2 699.00 -549.00 2 263.88
A10 Z 10×20 2 229.00 -578.00 2 224.26
A11 Z 10×20 2 018.00 -365.00 2 189.05
A12 Z 10×20 1 981.00 0.00 2 198.91
A13 Z 10×20 2 018.00 365.00 2 189.05
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定位 方向 尺寸/mm X/mm Y/mm Z/mm
A14 Z 10×10 3 617.00 0.00 2 282.63
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定位面A14信息

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定位 方向 尺寸/mm X/mm Y/mm Z/mm
A14 Z 10×10 3 617.00 0.00 2 282.63
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定位 方向 尺寸/mm X/mm Y/mm Z/mm
B XY Φ16 2 670.00 0.00 986.27
C Y 16×20 1 659.00 0.00 1 107.00
A1 Z 20×20 1 631.00 -46.00 1 105.50
A2 Z 20×20 2 000.00 -51.00 1 118.00
A3 Z 20×20 2 676.00 -66.00 986.27
A4 Z 20×20 2 676.00 69.00 986.27
A5 Z 20×20 2 000.00 54.00 1 118.00
A6 Z 20×20 1 631.00 62.00 1 105.50
A7 Z 16×16 1 314.00 14.00 1 180.60
A8 Z 30×40 1 675.00 218.00 897.22
A9 Z 25×40 2 577.00 189.00 898.79
A10 Z 25×40 2 577.00 -189.00 898.79
A11 Z 30×40 1 675.00 -186.00 897.22
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中通道定位基准信息

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定位 方向 尺寸/mm X/mm Y/mm Z/mm
B XY Φ16 2 670.00 0.00 986.27
C Y 16×20 1 659.00 0.00 1 107.00
A1 Z 20×20 1 631.00 -46.00 1 105.50
A2 Z 20×20 2 000.00 -51.00 1 118.00
A3 Z 20×20 2 676.00 -66.00 986.27
A4 Z 20×20 2 676.00 69.00 986.27
A5 Z 20×20 2 000.00 54.00 1 118.00
A6 Z 20×20 1 631.00 62.00 1 105.50
A7 Z 16×16 1 314.00 14.00 1 180.60
A8 Z 30×40 1 675.00 218.00 897.22
A9 Z 25×40 2 577.00 189.00 898.79
A10 Z 25×40 2 577.00 -189.00 898.79
A11 Z 30×40 1 675.00 -186.00 897.22
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零件名称 料厚/mm 质量/kg
中通道 1.4 9.5
中通道横梁Ⅰ 1.2 0.9
副仪表板支架 1.5 0.5
前地板左纵梁 1.2 2.1
前地板右纵梁 1.2 2.1
中通道加强支架 1.2 0.8
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冲压件料厚和质量信息

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零件名称 料厚/mm 质量/kg
中通道 1.4 9.5
中通道横梁Ⅰ 1.2 0.9
副仪表板支架 1.5 0.5
前地板左纵梁 1.2 2.1
前地板右纵梁 1.2 2.1
中通道加强支架 1.2 0.8
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白车身薄板冲压件自重变形非线性仿真分析
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刘永超 , 张建坤 , 马春辉 , 贡泽飞 , 李景鹏
汽车工艺与材料 | 视界 2024,(8): 7-11
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汽车工艺与材料 | 视界 2024, (8): 7-11
白车身薄板冲压件自重变形非线性仿真分析
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刘永超, 张建坤, 马春辉, 贡泽飞, 李景鹏
作者信息
  • 中国重型汽车集团有限公司, 济南 250000
  • 刘永超(1992—),男,硕士学位,主要研究方向为车身尺寸匹配技术。

Nonlinear Simulation Analysis of Gravity Deformation of Sheet Stampings for Body-in-White
Yongchao Liu, Jiankun Zhang, Chunhui Ma, Zefei Gong, Jingpeng Li
Affiliations
  • China National Heavy Duty Truck Group Corporation, Jinan 250000
出版时间: 2024-08-20 doi: 10.19710/J.cnki.1003-8817.20230277
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为分析自重变形对薄板冲压件尺寸检测合格率的影响,利用HyperMesh与Abaqus构建天窗顶盖外板和中通道焊接总成自重变形非线性联合仿真模型。结果表明,不同的摆放姿态克服自重变形的能力不同,凸放可以提高零件克服自重变形的能力,验证了自重变形非线性分析方法指导白车身薄板冲压件测量方案设计的可行性。

薄板冲压件  /  自重变形  /  非线性  /  仿真

In order to analyze the influence of gravity deformation on the size pass rate of sheet stampings, Hypermesh and Abaqus were used to construct the nonlinear co-simulation model of gravity deformation of the sunroof cover plate and the tunnel welding assembly. The results show that different placement positions have different abilities to overcome gravity deformation, and the convex placement can improve the ability of parts to overcome gravity deformation. The simulation results verify the feasibility of nonlinear analysis method of gravity deformation to guide the measurement scheme design of sheet stampings of BIW.

Sheet stampings  /  Gravity distortion  /  Nonlinearity  /  Simulation
刘永超, 张建坤, 马春辉, 贡泽飞, 李景鹏. 白车身薄板冲压件自重变形非线性仿真分析. 汽车工艺与材料, 2024 , (8) : 7 -11 . DOI: 10.19710/J.cnki.1003-8817.20230277
Yongchao Liu, Jiankun Zhang, Chunhui Ma, Zefei Gong, Jingpeng Li. Nonlinear Simulation Analysis of Gravity Deformation of Sheet Stampings for Body-in-White[J]. Automobile Technology & Material, 2024 , (8) : 7 -11 . DOI: 10.19710/J.cnki.1003-8817.20230277
白车身薄板冲压件尺寸大、结构复杂,自重变形会影响零件尺寸检测合格率[1-2]。在设计薄板冲压件测量方案时,需要综合考虑其在检具上摆放姿态和定位基准的数量[3],以减小自重变形对检测结果的影响。传统白车身薄板冲压件测量方案的设计往往依赖于过往车型资料和人员经验,但因工艺过程变更、零件形状变化和人员经验的影响,会出现摆放姿态不合理和定位基准数量不足无法满足克服自重变形要求的问题,甚至出现定位基准数量冗余的现象。定位基准数量冗余会导致零件与检具贴合不良,提高冲压件模具调试和焊接总成精度提升的难度。
利用HyperMesh与Abaqus构建接触非线性联合仿真模型,模拟不同摆放姿态和定位基准数量对自重变形的影响,为白车身薄板冲压件测量方案的设计提供指导。
白车身冲压件在检具上的摆放姿态要求与整车坐标系一致,鉴于测量操作方便性和工艺过程要求等,允许将零件旋转±90°或±180°[4]。将冲压件固定于检具上的一般过程为:首先将冲压件放在检具上,然后插入定位销,最后按照检测要求依次夹紧零件。在检具上判断冲压件质量时,通常更关注冲压件在自由状态(未夹紧)下的精度。
在夹紧之前,检具定位面与薄板冲压件表面因重力作用相互接触,并产生相对小滑移。接触滑移属于边界条件非线性问题[5],因此需要构建检具定位面与冲压件表面间的滑移非线性模型。白车身冲压件为薄板件,需要在抽取中性面后再进行网格划分,HyperMesh拥有丰富的有限元分析预处理功能,Abaqus具有强大的非线性分析能力,因此选择二者联合仿真建立白车身薄板冲压件自重变形非线性分析的模型。
根据冲压件测量方案关于摆放姿态与定位面的位置和大小的定义绘制定位面的数模,定位面的厚度设计为5 mm。冲压件和定位面数模转为stp格式导入HyperMesh进行前处理;若为焊接总成,可删除螺母、螺柱等附属件再导入HyperMesh,以降低模型的复杂程度。冲压件抽取中性面后划分网格,网格单元类型为壳单元;定位面可视为刚性体,划分为六面体网格,网格单元类型为实体单元。定义冲压件与定位面间的面接触属性。焊接总成的焊点采用fastener。冲压件和定位面的材料密度、弹性模量、泊松比和摩擦因数等参数如表1所示。前处理完成后导出为inp文件。
导入前处理inp文件,在Abaqus中分别建立每个定位面与冲压件的小滑移接触,小滑移接触参数采用默认设置。约束定位孔边缘节点在限制方向上的自由度,并在冲压件上施加重力。
某车型天窗顶盖外板X向长为2 083 mm,Y向宽为1 225 mm,Z向高为178 mm,料厚为0.7 mm,质量7.4 kg,定位基准如图1所示。其中BC为主辅定位孔,D1、D2、E1和E2为限制其旋转的辅助定位面,A1~A13为主定位基准面。定位基准信息如表2所示。
当位移边界条件为主定位孔B、辅助定位孔C,定位面D1、D2、E1和E2不起作用,仅定位面A1~A13与顶盖外板建立固定连接,即二者之间无滑移时,天窗顶盖外板的自重变形为线性问题。
天窗顶盖外板按照整车坐标系放置,即外表面向上(凸放)时,在重力作用下,天窗口后部沿Z轴负向的最大变形量为0.36 mm,如图2所示。
当天窗顶盖外板按照整车坐标系旋转180°放置,即外表面向下(凹放)时,在重力作用下,天窗口后部沿Z轴正向的最大变形量为0.36 mm,如图3所示。
图2图3可知,当天窗顶盖外板自重变形为线性模型时,无论凸放还是凹放,其自重变形量一致。
设置位移边界条件为:约束主定位孔B节点的5个自由度,释放Z向的移动自由度;约束辅助定位孔C节点的4个自由度,释放Y向和Z向的移动自由度;并在D1、D2、E1、E2和A1~A13与天窗顶盖外板之间建立小滑移接触。因为存在小滑移接触,这时顶盖外板的自重变形为非线性问题。
当天窗顶盖外板凸放时,在重力作用下,天窗口后部沿Z轴负向的最大变形量为0.57 mm,如图4所示。
当天窗顶盖外板凹放时,在重力作用下,天窗口后部沿Z轴正向的最大变形量为0.68 mm,如图5所示。
图4图5可知,当天窗顶盖外板自重变形为非线性模型时,凸放比凹放变形量小0.11 mm。说明凸放能提高天窗顶盖外板克服自重变形的能力。
通过图4图2对比分析可知,非线性凸放比线性凸放变形量大0.21 mm,说明在建立线性模型时,定位面A1~A13与天窗顶盖外板之间的固定连接限制了天窗顶盖外板在重力作用下与定位面之间的滑移,这种边界条件增大了天窗顶盖外板模型的刚度。白车身冲压件放在检具上的过程是先放件后夹紧,冲压件与检具定位面接触的瞬间,在重力作用下已产生小滑移,非线性自重变形的建模方式与实际更相符。
由4.1节的仿真结果可知,天窗顶盖外板检测时的摆放姿态应定义为凸放。由图4可知,天窗顶盖外板天窗口后部沿Z轴负向的最大变形量为0.57 mm,超过冲压件一般公差±0.5 mm,说明定位基准数量不足,需要增加定位面以克服自重变形。在天窗口后部中间位置增加定位面A14,如图6所示。定位面A14的信息如表3所示。
构建天窗顶盖外板非线性凸放模型,添加的位移边界条件为:约束主定位孔B节点的5个自由度,释放Z向的移动自由度;约束辅助定位孔C节点的4个自由度,释放Y向和Z向的移动自由度;在D1、D2、E1、E2和A1~A14与天窗顶盖外板之间建立小滑移接触。如图7所示,增加定位面A14后,在重力作用下,天窗口后部沿Z轴基本无变形;最大变形位置出现在天窗口两侧,沿Z轴负向最大变形量为0.16 mm,满足设计要求。
某车型中通道焊接总成由6个冲压件拼焊而成,X向长度为1 465 mm,Y向宽度为567 mm,Z向高度为311 mm,质量为15.9 kg,其定位基准如图8所示。定位基准信息如表4所示。6个冲压件料厚和质量信息如表5所示。
定义中通道焊接总成测量时按照整车坐标系凸放,添加的位移边界条件为:约束主定位孔B节点的5个自由度,释放Z向的移动自由度;约束辅助定位孔C节点的4个自由度,释放X向和Z向的移动自由度;并在A1~A11与中通道焊接总成之间建立小滑移接触。中通道焊接总成非线性自重变形如图9所示,沿Z轴负向的最大变形为0.15 mm。
取消定位面A2、A5、A7、A9和A10,中通道焊接总自重变形如图10所示,沿Z轴负向的最大变形量为0.15 mm,说明原定位基准设计冗余。
薄板冲压件与检具定位面接触的瞬间,在重力作用下,冲压件与检具定位面产生小滑移。冲压件与定位面之间建立固定连接的建模方式会增大冲压件的刚度,非线性自重变形的建模方式与实际更相符。
薄板冲压件在检具上不同的摆放姿态克服自重变形的能力不同,冲压件凸放可以提高自身刚度,克服自重变形的能力更强。
利用HyperMesh与Abaqus构建接触非线性联合仿真模型,可模拟薄板冲压件不同摆放姿态和定位基准数量对自重变形的影响,从而指导白车身薄板冲压件测量方案的设计。
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doi: 10.19710/J.cnki.1003-8817.20230277
  • 首发时间:2025-12-19
  • 出版时间:2024-08-20
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    中国重型汽车集团有限公司, 济南 250000
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