CN101419644A - Wheel applied load stress numerical analysis method considering residual stress - Google Patents
Wheel applied load stress numerical analysis method considering residual stress Download PDFInfo
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- CN101419644A CN101419644A CNA2008102343119A CN200810234311A CN101419644A CN 101419644 A CN101419644 A CN 101419644A CN A2008102343119 A CNA2008102343119 A CN A2008102343119A CN 200810234311 A CN200810234311 A CN 200810234311A CN 101419644 A CN101419644 A CN 101419644A
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Abstract
The invention discloses a numerical stress analyzing method for applied load of a wheel by considering residual stress, comprising the following steps: 1) the residual stress is calculated; 2) node information, unit information and residual stress data of finite element meshes of wheel castings are converted 3) the numerical stress analysis of the integral casting aluminum alloy wheel applied load is carried out with the residual stress considered. Compared with the prior numerical stress analysis of aluminum alloy wheel applied load, the numerical stress analyzing method for the applied load of the wheel by considering residual stress has the advantages of: 1) considering influences of the residual stress on the applied load of the wheel and ensuring the reliability of the wheel optimized design application; 2) improving the residual stress problem which can not be neglected in the optimizing design process of casting bearing components. The numerical stress analyzing method is applied to the structural analysis optimizing work of all the casting bearing components.
Description
Technical field
The present invention relates to a kind of Numerical analysis of stress method of automotive wheel plus load, especially relate to a kind of Numerical analysis of stress method of considering the wheel plus load of unrelieved stress.
Background technology
In short supply day by day along with the energy, automobile lightweight and energy-saving and cost-reducing requirement increase, and in order to realize the light-weight design of automotive wheel, design engineers press the physical dimension that stress is optimized spoke and wheel hub, but do not consider the influence of unrelieved stress during analysis.
Monoblock type Birmasil automotive wheel just exists unrelieved stress from creating itself, and its size depends on the casting residual stress that casting process produces: owing to thermal stress and wheel member solidify, the influence of the foundry engieerings such as asymmetry, casting and moulding of inhomogeneous, the shape of each several part wall thickness causes when cooling off structural stress and owing to the result of the combined action of the tissue of material and the inhomogeneous structural stress that causes of composition etc.; Also depend on unrelieved stress that machining causes and thermal treatment consumption to unrelieved stress.
Wheel as car load travel the part main bearing part be the most important safety component of left and right sides vehicle performance, the viewpoint of using value is more outstanding technically, and the existence of unrelieved stress all will produce directly influence for dimensional stability, fatigue strength and the stress corrosion etc. of wheel.Therefore, unrelieved stress is a key factor of can not ignore in the wheel optimized process.Carry out the wheel Study on residual stress, correctly determine the optimal design stress of wheel for how according to operating mode, guarantee its reliability of applying, have important practical significance.
The present invention utilizes the Stress Analysis Stress calculation module of ProCAST to calculate the casting residual stress of wheel foundry goods, scaled this value, final residual stress after subduing as machining, thermal treatment, result of calculation is transformed in the ANSYS software initial residual stress as wheel optimized design by program, consider the Numerical analysis of stress of the monoblock type cast aluminum alloy wheel plus load of unrelieved stress again, this reliability for the analysis of wheel casting structure provides assurance, and the work of researching and analysing of this respect report does not still have at present.
Hereinafter, unless special the qualification, unrelieved stress all refers to this three of unrelieved stress compound after unrelieved stress that casting residual stress, machining cause and thermal treatment are subdued.
Summary of the invention
1, goal of the invention
The objective of the invention is, at the deficiencies in the prior art, the residual stress problems of ignoring in the proposition monoblock type Birmasil automotive wheel optimal design process is investigated the influence of unrelieved stress to the car wheel structure analytic process, to improve the reliability of wheel optimized design.
2, technical scheme
To achieve these goals, the technical solution adopted in the present invention may further comprise the steps:
1) calculates unrelieved stress
At first utilize the Stress Analysis Stress calculation module of ProCAST to calculate the casting residual stress of monoblock type Birmasil automotive wheel.
2) nodal information, unit information and the unrelieved stress data of the finite element grid of wheel foundry goods are changed
Coding is transformed into the unrelieved stress component on nodal information, the unit information of the finite element grid of the wheel foundry goods of setting up and the wheel cast nodes that calculates in the ANSYS software in ProCAST.This step comprises,
1. unit information is done format conversion, and be read among the ANSYS by ProCAST;
2. with the stress data information separated of residual stress of casting and casting mold;
3. with casting residual stress to the data that can handle that are converted into ANSYS software, the casting residual stress value of during conversion ProCAST being calculated is scaled, final residual stress after subduing as machining and thermal treatment, and be loaded on the node of finite element grid unit.
3) Numerical analysis of stress of the monoblock type cast aluminum alloy wheel plus load of consideration unrelieved stress
Utilize ANSYS software boss face in the middle of wheel to apply the constraint of all degree of freedom, wheel is applied radial load, axial load and torque load respectively, consider the monoblock type cast aluminum alloy wheel Numerical analysis of stress of unrelieved stress.
3, beneficial effect
The present invention compares with the Numerical analysis of stress of existing aluminum-alloy wheel plus load, and following advantage is arranged:
1) considered the influence of unrelieved stress, guaranteed the reliability of wheel optimized design application the wheel plus load.
The residual stress problems of can not ignore in 2) the perfect casting bearing carrier optimal design process, this Numerical analysis of stress method is applicable to the structure analysis optimization work of all casting bearing carriers.
Description of drawings
Fig. 1 is the Exchange-Element.m program flow diagram;
Fig. 2 is the Read-Stress.m program flow diagram;
Fig. 3 is the Exchange-Stress.m program flow diagram.
Embodiment
Now the invention will be further described in conjunction with example.
1. the calculating of casting residual stress
The Stress Analysis Stress calculation module of utilizing ProCAST is that the casting residual stress of 6019 monoblock type Birmasil automotive wheel calculates to model.Adopt the thermo-elasto-plasticity model during calculating, this model does not directly count viscous effect, and it is thought and is elasticity before the material yield, then plasticity after the surrender, elastic modulus and yield stress are the functions of temperature, and when material during near fusing point, elastic modulus and yield stress all become 0.The wheel casting material is A356.2, and the massfraction of composition is: ω (Si)=7%, and ω (Mg)=0.33%, surplus is an aluminium, Poisson ratio σ=0.33.
The casting mold mold materials is done mould steel for H13 heat, the interfacial heat transfer coefficient h=1500W/m between the mould
2K, interfacial heat transfer coefficient h=1280W/m between mould and the foundry goods
2K.The casting pouring temperature is 705 ℃, and the initial preheat temperature of patrix is 360 ℃, and side form is 360 ℃, and counterdie is 430 ℃, and cavity filling process pressurization parameter sees Table 1.
Table 1. cavity filling process pressure parameter
Through the casting residual stress result of calculation after the 6019 monoblock type cast aluminum alloy wheel demouldings of 1490 time steps, part numerical value sees Table 2: the minimum stress value is 1.4246MPa, and maximum stress value is 88.65MPa.
Table 2. part of nodes casting residual stress component values
2. the conversion of the finite element grid nodal information of wheel foundry goods, unit information and unrelieved stress data
Because of ProCAST does not have the structure analysis function, utilize ANSYS software as the structure analysis platform, therefore need to solve this key issue of data transfer between two softwares.According to the concrete condition of each module of ProCAST and ANSYS software, need finish the work of two aspects: the one, the conversion of the finite element grid form of foundry goods 3D solid subdivision comprises nodal information, unit information; The 2nd, the casting residual stress that is calculated by ProCAST is converted to initial load in the ANSYS structure analysis.Utilize the MATLAB coding, nodal information, the unit information of the 6019 monoblock type cast aluminum alloy wheel finite element grids set up among the ProCAST and six the unrelieved stress components of each node of wheel that calculate are transformed in the ANSYS software.
(1) conversion of unit information
Wherein nodal information can directly be read among the ANSYS by ProCAST, any conversion that it goes without doing, and unit information need be done format conversion and could be read among the ANSYS by ProCAST.Utilize MATLAB to write units corresponding Transformation Program Exchange-Element.m, program flow diagram is seen Fig. 1.
1. the grid cell message file that reads ProCAST foundation is to internal memory;
2. judge and whether read several m, if not, then finish to calculate smaller or equal to the unit number;
If m smaller or equal to the unit number, the m that then gets unit file is capable;
4. with the capable discernible unit information form of ANSYS that is arranged in of m;
5. save as the unit information file of ANSYS identification, read several m and add 1;
6. continue whether to judge m, carry out 2-5 step circulation,, finish up to greater than the grid cell number smaller or equal to the unit number.
The Exchange-Element.m program is as follows:
clear?all；％
clc；
elem_number＝618556；
node_number＝127614；
M=1; % circulation m initialize;
fp1＝fopen(′wheel.ansys.elem′，′r′)；
fp2＝fopen(′wheel.ele′，′a+′)；
whilem<＝elem_numbern＝(m-1)
*83；
fseek(fp1，n，-1)；
a＝fgets(fp1)；
ele_procast＝str2num([a(1:8)a(8:15)a(16:22)a(23:29)a(53:59)a(71:77)])；fprintf(fp2，′％6d％6d％6d％6d％6d％6d％6d％6d％6d％6d％6d％6d％6d％6d\n′，ele_procast(1)，ele_procast(2)，ele_procast(3)，ele_procast(3)，ele_procast(4)，ele_procast(4)，ele_procast(4)，ele_procast(4)，ele_procast(5)，2，2，1，0，m)；
m＝m+1；
end
fclose(′all′)；
Utilize the Exchange-Element.m program that 6019 monoblock type Birmasil automotive wheel ProCAST finite element grids are transformed among the ANSYS.
(2) residual stress of casting and casting mold die casting unrelieved stress separates
Also comprised unrelieved stress on the casting mold mould node when in the casting residual stress data file that ProCAST calculates the wheel residual stress of casting being arranged (if do not calculate unrelieved stress on the casting mold, six components of stress on the casting mold node are 0, output on the unrelieved stress file as integral body equally), the casting mold stress data is unnecessary when utilizing ANSYS to carry out the car wheel structure analysis, therefore needs the stress data information separated of foundry goods and casting mold.Utilize MATLAB to write the stress data that the Read-Stress.m program is come separating casting and casting mold, program flow diagram is seen Fig. 2.
1. the casting residual stress file that reads ProCAST calculating is to internal memory;
2. wheel for inputting hub casts nodal information;
3. judge and whether read several m, if not, then finish to calculate smaller or equal to the node sum;
4. if m, judges further then that whether read several m is cast nodes, if not, then reads several m and adds 1 smaller or equal to the node sum;
5. if m is a cast nodes, then get the casting residual stress of m node;
6. preserve all information of m node;
7. read several m and add 1, carry out 3-6 step circulation,, finish up to greater than the node sum.
The Read-Stress.m program is as follows:
clear?all；
clc；
elem_number＝618556；
node_number＝127614；
m＝1；
p＝0；
Fp8=fopen (' wheel.ntl ', ' r '); % opens the casting residual stress file wheel.ntl that ProCAST calculates;
fp9＝fopen(′wheel_stress.txt′，′a+′)；
while?m<10&m<＝node_number
n＝11+96*p+m*50；
fseek(fp8，n，-1)；
a＝fgets(fp8)；
fprintf(fp9，′％s′，a)；
m＝m+1；
p＝p+1；
end
while m>＝10&m<100&m<＝node_number
n＝11+96*p+9*50+(m-9)*51；
fseek(fp8，n，-1)；
a＝fgets(fp8)；
fprintf(fp9，′％s′，a)；
m＝m+1；
p＝p+1；
end
.% get hundred, thousand successively, the circulation of the node of myriabit;
.
.
while?m<＝1000000&m>＝100000&m<＝node_number
n＝11+96*p+9*(50)+90*51+900*52+9000*53+90000*54+(m-99999)*55；
fseek(fp8，n，-1)；
a＝fgets(fp8)；
fprintf(fp9，′％s′，a)；
m＝m+1；
p＝p+1；
end
fclose(′all′)；
Utilize above Read-Stress.m program only to be contained the casting residual stress file wheel_stress.txt of 6019 aluminum-alloy wheel foundry goods nodes.
(3) conversion of unrelieved stress numerical value
The stress file layout that ANSYS accepts is as shown in table 3:
The stress file layout of table 3.ANSYS cell node
Six unrelieved stress components of the node that comparison sheet 2ProCAST calculates and the stress file layout of showing 3ANSYS acceptance, two file layouts differ greatly as can be known.Utilize MATLAB to write the Exchange-Stress.m program and realize the data-switching of the casting residual stress of ProCAST calculating to ANSYS software, the casting residual stress value of during conversion ProCAST being calculated is dwindled in 50% ratio, final residual stress after subduing as machining and thermal treatment, the Exchange-Stress.m program flow diagram is seen Fig. 3.
1. read the wheel hub casting residual stress file that Read-Stress generates;
2. wheel hub casting residual stress numerical value is taken advantage of 0.5, as being subduing casting residual stress after machining stress and the thermal treatment;
3. read wheel hub cast nodes information, unit information among the Exchange-Element;
4. judge and whether read several m, if not, then finish to calculate smaller or equal to the unit sum;
5. if m smaller or equal to the unit sum, then gets the node k of m unit;
6. search the stress value of node k;
7. preserve the stress value of node k according to ANSYS stress file layout;
8. read several m and add 1, carry out 4-7 step circulation,, finish up to greater than the unit sum.
The Exchange-Stress.m program is as follows:
clear?all；
clc；
elem_number＝618556；
node_number＝127614；
ele_lis＝[]；
ele_num＝[]；
ss＝0.5*[
]；
sss＝1:1:node_number；
s＝[sss′ss]；
i＝1；
fp4＝fopen(′istress.ist′，′a+′)；
fprintf(fp4，′!************STRESS?INITIALIZATION?FILE?FORANSYS************\n′)；
fprintf(fp4，′!\n′)；
fprintf(fp4，′!This?file，istress.ist，contains?initial?stress?data\n′)；
fprintf(fp4，′!for?solid185?elements.\n′)；
fprintf(fp4，′!\n′)；
while?i<＝length(ele_num)
fprintf(fp4，′!Stress?for?element％d\n′，ele_num(i))；
fprintf(fp4，′!Sx?Sy?Sz?Sxy?Syz?Sxz\n′)；
fprintf(fp4，′eis，％d\n′，ele_num(i))；
k＝1；
p＝1；
node＝ele_lis(i，p)；
while?k<＝node_number
find_node＝s(k，1)；
if?node＝＝find_node
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
k＝node_number；
end
k＝k+1；
end
k＝1；
p＝2；
node＝ele_lis(i，p)；
while?k<＝node_number
find_node＝s(k，1)；
if?node＝＝find_node
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
k＝node_number；
end
k＝k+1；
end
k＝1；
p＝3；％p
node＝ele_lis(i，p)；％node
while?k<＝node_number
find_node＝s(k，1)；
if?node＝＝find_node
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
k＝node_number；
end
k＝k+1；
end
k＝1；
p＝5；
node＝ele_lis(i，p)；
while?k<＝node_number
find_node＝s(k，1)；
if?node＝＝find_node
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
fprintf(fp4，′％12.4e，％12.4e，％12.4e，％12.4e，％12.4e，％12.4e\n′，s(k，2)，s(k，3)，s(k，4)，s(k，5)，s(k，6)，s(k，7))；
k＝node_number；
end
k＝k+1；
end
fprintf(fp4，′!\n′)；
i＝i+1；
end
fprintf(fp4，′!\n′)；
fprintf(fp4，′!End?of?initial?stress?file\n′)；
fprintf(fp4，′!***************************************************************\n′)；
fclose(′all′)；
Obtain the stress file istress.ist of ANSYS identification after the conversion, it is loaded on the node that is transformed into 6019 monoblock type cast aluminum alloy wheel finite element grid unit among the ANSYS as initial stress values.
3. the Numerical analysis of stress (1) of not considering the aluminum alloy automobile wheel plus load of unrelieved stress applies radial load to wheel
Utilize ANSYS software boss face in the middle of 6019 monoblock type cast aluminum alloy wheels to apply all degree of freedom constraints, axial 80% place applies the radially load of 8000N to wheel rim.
(2) wheel is applied axial load
Boss face applies all degree of freedom constraints in the middle of the 6019 monoblock type cast aluminum alloy wheels equally, and spoke is radially applied the load of axial 8000N in 50% place.
(3) wheel is applied torque load
Retrain the samely, wheel rim is applied circumferential load perpendicular to axial direction over against axial 70% place of both sides, size is 8000N, and direction is opposite.
4 consider the Numerical analysis of stress of the aluminum alloy automobile wheel plus load of unrelieved stress
(1) the wheel stress numerical analysis of the radial loaded of consideration unrelieved stress
Boss face applies all degree of freedom constraints in the middle of 6019 monoblock type cast aluminum alloy wheels, and axial 80% place of 6019 monoblock type cast aluminum alloy wheel wheel rims after the loading unrelieved stress is applied the radially load of 8000N.
(2) the wheel stress numerical analysis of the axial loading of consideration unrelieved stress
Retrain the samely, the 6019 monoblock type cast aluminum alloy wheel spokes that load after the unrelieved stress are radially applied the load of axial 8000N in 50% place.
That (3) considers unrelieved stress applies the wheel stress numerical analysis of torque load to wheel
Retrain the samely, the 6019 monoblock type cast aluminum alloy wheel wheel rims that load after the unrelieved stress are applied circumferential load perpendicular to axial direction over against axial 70% place of both sides, size is 8000N, and direction is opposite.
5 comparative analysiss
The comparison of the maximum stress under the table 4. different loads condition
The extreme value of stress compares under the table 4 pair different loads, and when wheel was only applied radial load, the equivalent stress minimum value of wheel was 0.00MPa, and maximum stress value is 119.00MPa; Considered the after-applied same radial load of unrelieved stress, the stress minimum value is raised to 1.28MPa from 0.00MPa, and maximal value drops to 117.00MPa from 119.00MPa.When wheel was applied axial load, under the situation of considering unrelieved stress, the equivalent stress minimum value rose to some extent, and maximal value descends to some extent; When wheel was applied torque load, under the situation of considering unrelieved stress, equivalent stress minimum value and maximal value all rose to some extent.
Consider more than after the unrelieved stress that variation has taken place equivalent stress under the various load conditions, this is because the direction of unrelieved stress is identical with the direction possibility of the equivalent stress of imposed load generation, also may be opposite, if both directions are identical, stress stack at the node place, thereby increase the stress value at this node place, then cancel out each other when direction is inconsistent, reduced its equivalent stress.Both illustrated that plus load after having considered unrelieved stress, the stress of wheel were that numerical value or direction have all taken place to redistribute.Therefore, unrelieved stress is the amount that cannot ignore as the key factor that influences wheel stress distribution under the plus load effect.
The automotive wheel Numerical analysis of stress method of the plus load of this consideration unrelieved stress is more pressed close to the fact, the similarities and differences of the equivalent stress direction that produces just because of the direction of unrelieved stress and plus load have caused the stack of stress or have offset relation, thereby have formed the initial dynamic stress state of automotive wheel after installation.
Claims (2)
1, a kind of Numerical analysis of stress method of considering the wheel plus load of unrelieved stress is characterized in that, may further comprise the steps:
1) calculates unrelieved stress
Utilize the Stress Analysis Stress calculation module of ProCAST to calculate the casting residual stress of monoblock type Birmasil automotive wheel;
2) nodal information, unit information and the unrelieved stress data of the finite element grid of wheel foundry goods are changed
Coding is transformed into the unrelieved stress component on nodal information, the unit information of the finite element grid of the wheel foundry goods of setting up and the wheel cast nodes that calculates in the ANSYS software in ProCAST.
3) Numerical analysis of stress of the monoblock type cast aluminum alloy wheel plus load of consideration unrelieved stress
Utilize ANSYS software boss face in the middle of wheel to apply the constraint of all degree of freedom, wheel is applied radial load, axial load and torque load respectively, consider the monoblock type cast aluminum alloy wheel Numerical analysis of stress of unrelieved stress.
2, a kind of Numerical analysis of stress method of considering the wheel plus load of unrelieved stress according to claim 1 is characterized in that step 2) further comprise,
1) unit information is done format conversion, and be read among the ANSYS by ProCAST;
2) with the stress data information separated of residual stress of casting and casting mold;
3) with casting residual stress to the data that can handle that are converted into ANSYS software, the casting residual stress value of during conversion ProCAST being calculated is scaled, final residual stress after subduing as machining and thermal treatment, and be loaded on the node of finite element grid unit.
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| CN101887472B (en) * | 2009-05-12 | 2014-01-01 | 通用汽车环球科技运作公司 | Methods of predicting residual stresses and distortion in quenched aluminum castings |
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