CN105279343B - Welding spot arrangement optimization method based on welding spot stress homogenization - Google Patents
Welding spot arrangement optimization method based on welding spot stress homogenization Download PDFInfo
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Abstract
The invention discloses a welding spot arrangement optimization method based on welding spot stress homogenization, which comprises the following steps: establishing a finite element model of an initial welding structure comprising a plurality of welding points; applying constraint and load to the initial welding structure in the finite element model to obtain the stress condition of each welding point; establishing an optimized mathematical model of welding spot arrangement by taking the minimum sum of the stresses borne by all welding spots as an optimization target and the contribution value of each welding spot as a design variable; and determining whether the corresponding welding points are reserved according to the contribution values of the welding points to obtain the optimized welding point arrangement. The invention is based on the structural topology optimization design technology, so that the stress distribution of each optimized welding point is uniform, the failure of the welding point in the bearing process is effectively reduced under the condition of ensuring the dynamic and static strength and rigidity of the welding structure, and the number of the welding points is reduced.
Description
Technical Field
The invention relates to the field of automobile part processing, in particular to a welding spot arrangement optimization method based on welding spot stress homogenization.
Background
Resistance spot welding is one of pressure welding, and is most widely applied in automobile production, such as a vehicle body structure, a seat framework structure and the like. In a typical vehicle body structure, 3000-5000 welding points are usually contained, the arrangement of the welding points directly influences the static and dynamic strength and rigidity of the structure, and the number of the welding points influences the complexity of the welding process of the structure. Therefore, under the condition of meeting the overall static and dynamic strength and rigidity of the structure, the welding spot positions are reasonably arranged, the number of the welding spots and the failure of the welding spots under the loaded condition are reduced as much as possible, and the welding structure has important significance in improving the performance of the welding structure and reducing the manufacturing cost.
At present, an empirical design method is generally adopted to carry out welding spot arrangement design of a welding structure, and relevant performances such as rigidity, fatigue and the like of the structure are checked to carry out correction, so that a reasonable and effective welding spot arrangement design method is lacked.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a welding spot arrangement optimization method based on welding spot stress homogenization, which can enable all welding spots in an optimized welding spot arrangement form to be uniformly distributed in stress, effectively reduce the failure of the welding spots in the bearing process under the condition of ensuring the dynamic and static strength and rigidity of a welding structure, and reduce the number of the welding spots and the welding cost.
In order to achieve the technical effect, the invention discloses a welding spot arrangement optimization method based on welding spot stress homogenization, which comprises the following steps:
establishing a finite element model of an initial welding structure comprising a plurality of welding points;
applying constraint and load to the initial welding structure in the finite element model to obtain the stress condition of each welding point;
establishing an optimized mathematical model of the welding spot arrangement shown in the formula (1) by taking the minimum sum of the stresses borne by all welding spots as an optimization target and the contribution value x of each welding spot as a design variable;
wherein n is the number of bonding points; v is the volume of the optimized welding spot; v0To optimize the volume of the front welding spot; v is volume fraction; sigmai(x) The stress on the ith welding spot is the magnitude of the stress;
and determining whether the corresponding welding points are reserved according to the contribution value x of each welding point to obtain the optimized welding point arrangement.
The invention is further improved in that the established finite element model of the initial welding structure simulates a welding part to be welded by the shell unit, simulates a welding point by the combination of the solid unit and the rod unit, and comprises a plurality of welding points which are uniformly distributed.
In a further development of the invention, a finite element model of an initial weld structure comprising a plurality of weld spots is created, comprising:
simulating a weldment to be welded of an initial welding structure with a shell unit, wherein the shell unit comprises a first simulation plate and a second simulation plate;
overlapping the first simulation plate and the second simulation plate to form an overlapping area;
simulating welding spots by combining a solid unit and a rod unit, and uniformly distributing a plurality of welding spots in the overlapping area for welding the first simulated plate and the second simulated plate to form an initial welding structure;
and establishing a finite element model for simulating the initial welding structure.
The invention is further improved in that when the first simulation plate and the second simulation plate are overlapped to form an overlapped area, a hollow area is formed on the first simulation plate or the second simulation plate in the overlapped area, a plurality of welding points are uniformly distributed in the overlapped area except the hollow area, an initial welding structure simulating the automobile seat back is formed, and a finite element model simulating the initial welding structure of the automobile seat back is established.
The further improvement of the invention is that the hollowed-out area is two parallel rectangular areas, and 19 welding points are uniformly distributed in the overlapping area outside the two rectangular areas.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
the invention provides a welding spot arrangement optimization method of a welding structure based on a structural topology optimization design technology, which comprises the steps of simulating a welding part to be welded by a shell unit, simulating a welding spot by the combination of a solid unit and a rod unit, and establishing a finite element model of the welding structure comprising a plurality of welding spots which are uniformly distributed; establishing an optimized mathematical model of welding spot arrangement by taking the minimum sum of the stresses borne by all welding spots as an optimization target and the contribution value of each welding spot as a design variable so as to obtain a structure with uniform stress of the welding spots; the optimized welding spot arrangement form has the advantages that stress distribution of all welding spots is uniform, the optimized welding spot arrangement can be automatically distributed according to the loading condition of the welding structure, failure of the welding spots in the bearing process is effectively reduced under the condition that dynamic and static strength and rigidity of the welding structure are guaranteed, the number of the welding spots is reduced, and welding cost is reduced.
Drawings
FIG. 1 is a schematic diagram of a lap bending test sample of a comparative welding structure based on the welding spot arrangement optimization method for homogenizing the stress of the welding spots.
FIG. 2 is a schematic view of the distribution of load positions of lap-joint bending test samples of a comparative welding structure based on the welding spot arrangement optimization method for uniformizing the stress of the welding spots.
FIG. 3 is a schematic diagram of deformation of a lap bending test sample of a comparative welding structure based on the welding spot arrangement optimization method for uniformizing stress of welding spots.
FIG. 4 is a schematic diagram of a finite element model for solder joint layout optimization according to an embodiment of the solder joint layout optimization method based on solder joint stress homogenization of the present invention.
FIG. 5 is a schematic distribution diagram of high-density solder points remained after optimization according to an embodiment of the solder joint arrangement optimization method based on uniform stress of solder joints.
FIG. 6 is a schematic view of a welding structure after the welding spots are optimally arranged according to the embodiment of the welding spot arrangement optimization method based on the welding spot stress homogenization.
FIG. 7 is a schematic diagram of deformation of a welding structure after optimization of welding spot arrangement according to an embodiment of the welding spot arrangement optimization method based on uniform stress of welding spots.
FIG. 8 is a statistical chart of the number of welding spots and the stress values after and before optimization of the welding spot arrangement optimization method based on the welding spot stress homogenization of the invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
The invention discloses a welding spot arrangement optimization method based on welding spot stress homogenization, which is based on a structural topology optimization design technology and aims to ensure that all welding spots in an optimized welding spot arrangement form are uniformly stressed, effectively reduce the failure of the welding spots in the bearing process under the condition of ensuring the dynamic and static strength and rigidity of a welding structure, reduce the number of welding spots and reduce the welding cost.
The main design idea of the welding spot arrangement optimization method based on welding spot stress homogenization comprises the following steps:
(1) a finite element model of an initial weld structure comprising a plurality of weld points is created.
And simulating a welding part to be welded by using the shell unit, simulating a welding spot by using the combination of the solid unit and the rod unit, and establishing a finite element model of an initial welding structure containing more uniformly distributed welding spots.
(2) Finite element analysis was performed on the initial weld structure.
And (3) applying constraint and load to the initial welding structure in the established finite element model, solving, and analyzing the stress condition of each welding point and the deformation of the welding part.
(3) And establishing an optimized mathematical model of welding spot arrangement.
The method comprises the steps of taking the minimum sum of the stress borne by a unit connected with a welding spot as an optimization target (wherein the unit connected with the welding spot is a unit corresponding to the welding spot in a finite element model, so that the stress condition of the unit connected with the welding spot represents the stress condition of the corresponding welding spot), and establishing an optimization mathematical model of the welding spot arrangement shown in the formula (1) by taking the contribution value x of each welding spot as a design variable.
In the formula: n is the number of solder points; v is the volume of the optimized welding spot; v0To optimize the volume of the front welding spot; v is volume fraction; sigmai(x) The stress borne by the ith welding spot connecting unit is large or small;
the established optimization mathematical model takes the minimum sum of the stresses borne by all welding spots as an optimization target to obtain a structure with uniform stress of the welding spots.
(4) And optimizing iteration based on the structural topology optimization technology.
The method comprises the steps of adopting a variable design variable (contribution value x) method to carry out arrangement optimization on welding spots of an initial welding structure, namely calculating the contribution degree of the design variable (contribution value x) of each welding spot to an optimization target in an optimization iteration mode by changing the design variable (contribution value x) of an optimization mathematical model, and obtaining the contribution value x of each welding spot through repeated optimization iteration; and determining whether the welding spot is reserved according to the contribution value x of each welding spot, wherein when the contribution value x of the welding spot reaches a certain standard value, the welding spot is a high-density welding spot, and the welding spot with the contribution value x not reaching the standard is a low-density welding spot. The high-density welding points greatly contribute to an optimization target and need to be reserved; and the low-density welding points have small contribution to the optimization target and can be deleted. The optimization purpose is achieved through repeated optimization iteration, the arrangement condition of the reserved high-density welding spots is used as the optimized welding spot arrangement, and the optimized welding spot arrangement can be automatically distributed according to the loading condition of the welding structure.
The contribution degree of the design variable of each welding spot to the optimization target is the proportion of the variation of the design variable of each welding spot to the total variation of the optimization target, the contribution degree of the welding spot with larger specific gravity is larger, the influence on the sum of the stresses borne by all the welding spots is larger, and the welding spots are mainly bearing welding spots and need to be reserved; the contribution degree of the welding spots with smaller specific weight is smaller, the influence on the sum of the stresses borne by all the welding spots is smaller, and the welding spots with small bearing capacity can be deleted.
(5) And analyzing and verifying results.
After the optimized welding spot arrangement is obtained, establishing a finite element model of a comparison welding structure based on a method for establishing a finite element model of an initial welding structure, wherein a welding piece which is the same as the initial welding structure is adopted in the comparison welding structure, and a plurality of welding spots are uniformly distributed; and applying constraint and load which are completely the same as the constraint and load applied in the finite element model of the initial welding structure before to the finite element model of the comparison welding structure to obtain the stress condition of the comparison welding structure, comparing the stress condition with the optimized welding spot arrangement, and judging whether the optimization scheme of the welding spot arrangement meets the design requirement. The optimization result is verified mainly by observing the optimized welding spot arrangement and comparing the stress condition of the welding spots in the welding structure and the deformation of a welding part. The design requirement is that all welding spots in the optimized welding spot arrangement are uniformly distributed in stress and the deformation of the welding structure of the optimized welding spot arrangement is basically kept or smaller than that of the comparative welding structure, so that the effect of effectively reducing the failure of the welding spots in the bearing process under the condition of ensuring the dynamic and static strength and rigidity of the welding structure is achieved.
The welding point arrangement optimization method based on welding point stress homogenization is applied to a concrete lap joint bending sample simulating a welding structure of an automobile seat backrest, and further description is provided for implementation and effect of the method, specifically as follows:
establishing a finite element model of a comparative welding structure
To facilitate explanation of the technical problem to be solved by the present invention, first, as shown in fig. 1, a sample for a lap bending test simulating a welded structure of a seat back of an automobile seat is established in a finite element as a finite element model of a comparative welded structure. The method mainly comprises the following steps: in the structural topological optimization design technology, a shell unit is used for welding parts to be welded, and the shell unit comprises a first simulation plate 11 (a 2mm steel plate) and a second simulation plate 12 (a 0.9mm steel plate); overlapping one side of the first simulated board 11 and one side of the second simulated board 12 to form an overlapped area 13; simulating welding spots 14 by combining the solid units and the rod units, wherein 9 welding spots 14 are uniformly distributed in the overlapping area 13 and are used for welding the overlapping areas 13 of the first simulation plate 11 and the second simulation plate 12 together, the second simulation plate 12 is arranged above the first simulation plate 11, and two rectangular hollow areas 111 avoiding the welding spots 14 are formed in the overlapping area 13 of the first simulation plate 11 positioned below to form a welding structure simulating the seat back of the automobile seat; finally, a finite element model simulating the welding structure of the automobile seat back as shown in fig. 1 is established as a finite element model of a comparative welding structure.
Then, constraints 16 are respectively applied to the other end portion of the first simulated sheet material 11 and the other end portion of the second simulated sheet material 12 outside the overlap region 13, and six degrees of freedom of the first simulated sheet material 11 and the second simulated sheet material 12 are limited; and 4 downward loads 15 of 1000N were applied collectively to the second simulated sheet material 12 in the lap zone, with the position distribution of the 4 loads 15 being shown in fig. 2.
(II) simulation result analysis
And (4) carrying out simulation result analysis in the finite element model. The stress condition of each welding point in the welding structure and the deformation of a sample are firstly analyzed. The simulation analysis result is shown in fig. 3, wherein 9 welding points are marked with 1-9 labels, the stress of the welding point 1 is 836.5-982 MPa, the stress of the welding point 2 is 109-254.5 MPa, the stress of the welding point 3 is 691-836.5 MPa, the stress of the welding point 4 is 1273-1419 MPa, the stress of the welding point 5 is 400-545.5 MPa, the stress of the welding point 6 is 691-836.5 MPa, the stress of the welding point 7 is 545.5-691 MPa, the stress of the welding point 8 is 109-254.5 MPa, and the stress of the welding point 9 is 400-545.5 MPa. Therefore, through the finite element analysis of the comparative welding structure obtained by the sample for simulating the lap bending experiment of the welding structure of the automobile seat back, the maximum stress borne by the welding points is 1419MPa, the minimum stress borne by the welding points is 109MPa, and the stress of each welding point is uneven, so that the welding points with large stress can lose effectiveness in the loading process to influence the service performance of the welding parts.
(III) solder joint layout optimization
In order to reduce the failure of welding points in the stress process of the welding structure and reduce the stress distribution difference of each welding point, the invention adopts the welding point distribution optimization method based on the welding point stress homogenization to carry out the distribution optimization design on the welding points. Firstly, the design space of the optimized arrangement of the welding spots is increased to 19 on the basis of the original 9 welding spots, and the welding spots are more densely distributed according to the principle that one welding spot is additionally arranged between the adjacent welding spots of the original 9 welding spots to form a finite element model of the optimized design shown in fig. 4, the types of the welding spots are selected from the combination of the solid units and the rod units, and the applied boundary conditions (constraint and load) are the same as those of the lap-joint bending experiment of the 9 welding spots.
Establishing an optimized mathematical model of the welding spot arrangement shown in the formula (1) by taking the minimum sum of the stresses borne by all welding spots as an optimization target and the contribution value x of each welding spot as a design variable;
wherein n is the number of bonding points; v is the volume of the optimized welding spot; v0To optimize the volume of the front welding spot; v is volume fraction; sigmai(x) The stress on the ith welding spot is the magnitude of the stress;
and (4) carrying out optimization solution according to the optimization mathematical model of the formula (1). And setting the volume constraint V to be 50%, and optimally designing the welding spot arrangement of the welding structure. By changing only the design variables of the optimized mathematical model (the contribution values x of the respective pads), for example, when any effective data value of 0 to 1 is assigned to each of the contribution values x of 19 pads (x ═ 0.1, 0.2, 0.3, 0.33, … …), a plurality of sets of objective functions are obtained, the case where the sum of the plurality of sets of objective functions is minimum is taken as an optimization target, the contribution values x of 19 pads in the set that satisfies the optimization target are taken as the contribution values x of the 19 pads that are finally determined, and then whether the respective pads are high-contribution pads or not is determined according to the magnitude of the contribution values x that are finally determined for the respective pads, the pads that are determined as high-contribution pads are retained, and the pads that are determined as low-contribution pads are deleted. The circled pads in fig. 5 are reserved high density pads, and the non-circled pads are deletable low density pads, resulting in an optimized pad layout. According to the optimized welding spot arrangement result, the distribution density of the reserved welding spots near the load is higher according to the characteristics of the load loading position, and the load can be effectively shared. In addition, two welding spots reserved at one end far away from the load are distributed at the stress end, so that the deformation of the welding part can be reduced.
(IV) analysis of optimization results
From the high density of solder joints retained in fig. 5, a solder joint arrangement optimization scheme is summarized. As shown in fig. 6, for the optimized solder joint arrangement, the number of solder joints is 8, which is reduced by 11.1% compared with the original scheme (lap bending test with 9 solder joints).
(V) verification of solder joint arrangement optimization scheme
And reestablishing an optimized welding structure according to the welding spot arrangement optimization scheme, wherein the welding spot arrangement adopts the optimized arrangement scheme of 8 welding spots, the welding part still adopts the first simulated plate 11 and the second simulated plate 12 of the sample of the lap joint bending experiment of the previous 9 welding spots, the lap joint mode, the applied constraint and the load are not changed, and only the arrangement of the welding spots is changed, so that the comparative analysis is convenient to perform.
As shown in FIG. 7, after the solder joint arrangement is optimized, the deformation of the experimental sample is carried out, the 8 solder joints are given 1-8 labels, and the stress of the solder joint 1 is measured to be 840.1-924.3 MPa, the stress of the solder joint 2 is 755.9-840.1 MPa, the stress of the solder joint 3 is 503.5-587.6 MPa, the stress of the solder joint 4 is 251.0-335.1 MPa, the stress of the solder joint 5 is 419.3-503.5 MPa, the stress of the solder joint 6 is 166.8-251.0 MPa, the stress of the solder joint 7 is 503.5-587.6 MPa, and the stress of the solder joint 8 is 840.1-924.3 MPa. Therefore, after the arrangement of the welding spots is optimized, the maximum stress borne by the welding spots is 924.3MPa, which is reduced by 34.86% compared with that before the optimization. The maximum displacement of the welding structure before the arrangement and optimization of the welding spots is 27.1mm, the maximum displacement of the welding structure after the arrangement and optimization is 27.5mm, and the structural rigidity basically keeps the original rigidity. Therefore, under the condition that the structural rigidity is basically unchanged, the stress of welding spots in the loading process is reduced, the bearing performance of the welding structure is improved, the number of the welding spots is reduced, the welding cost is reduced, and the use requirement is met.
As shown in fig. 8, the statistics of the number of the solder joints and the stress values after the optimization and before the optimization are shown. As can be seen from fig. 8, before optimization, the stress distribution of the solder joints is relatively dispersed, i.e., some solder joints are subjected to excessive stress and fail. After the arrangement optimization of the welding spots is carried out, the stress of most welding spots is mainly concentrated in the range of 300-600MPa, the distribution of the stress of each welding spot is uniform, the number of failure welding spots can be effectively reduced, and the optimized arrangement of the welding spots can be automatically distributed according to the loading condition of the welding structure.
While the present invention has been described in detail and with reference to the accompanying drawings and examples, it will be apparent to one skilled in the art that various changes and modifications can be made therein. Therefore, certain details of the embodiments are not to be interpreted as limiting, and the scope of the invention is to be determined by the appended claims.
Claims (5)
1. A welding spot arrangement optimization method based on welding spot stress homogenization is characterized by comprising the following steps:
establishing a finite element model of an initial welding structure containing a plurality of welding spots, and adding the welding spots between adjacent welding spots on the basis of the welding spots in the initial welding structure to obtain the finite element model of the initial welding structure with more densely and uniformly distributed welding spots;
applying constraint and load to the initial welding structure in the finite element model to obtain the stress condition of each welding point;
establishing an optimized mathematical model of the welding spot arrangement shown in the formula (1) by taking the minimum sum of the stresses borne by all welding spots as an optimization target and the contribution value x of each welding spot as a design variable;
wherein n is the number of bonding points; v is the volume of the optimized welding spot; v0To optimize the volume of the front welding spot; v is volume fraction; sigmai(x) The stress on the ith welding spot is the magnitude of the stress;
and determining whether the corresponding welding points are reserved according to the contribution value x of each welding point to obtain the optimized welding point arrangement.
2. The solder joint arrangement optimization method based on solder joint stress homogenization of claim 1, wherein: the established finite element model of the initial welding structure simulates a welding part to be welded of the initial welding structure by the shell unit, simulates a welding point by the combination of the solid unit and the rod unit, and comprises a plurality of welding points which are uniformly distributed.
3. The method of claim 1, wherein the creating a finite element model of an initial weld configuration including a plurality of weld spots comprises:
simulating a weldment to be welded of an initial welding structure with a shell unit, wherein the shell unit comprises a first simulation plate and a second simulation plate;
overlapping the first simulation plate and the second simulation plate to form an overlapping area;
simulating welding spots by combining a solid unit and a rod unit, and uniformly distributing a plurality of welding spots in the overlapping area for welding the first simulated plate and the second simulated plate to form an initial welding structure;
and establishing a finite element model for simulating the initial welding structure.
4. The solder joint arrangement optimization method based on solder joint stress homogenization of claim 3, wherein: the first simulation panel with the overlap joint of second simulation panel when forming the overlap joint region, through in the overlap joint region first simulation panel or form the fretwork region on the second simulation panel outside the fretwork region evenly distributed is a plurality of the solder joint forms the initial welded structure of simulation car seat back of the chair, establishes the simulation the finite element model of the initial welded structure of car seat back of the chair.
5. The solder joint arrangement optimization method based on solder joint stress homogenization according to claim 4, wherein: the hollow areas are two parallel rectangular areas, and 19 welding points are uniformly distributed in the overlapping area outside the two rectangular areas.
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| CN108362561B (en) * | 2018-02-02 | 2020-06-09 | 上海理工大学 | Method for determining mechanical properties of materials of welding seam and welding heat affected zone |
| CN109492294A (en) * | 2018-11-02 | 2019-03-19 | 威马智慧出行科技（上海）有限公司 | A kind of solder joint design method and equipment |
| CN110595919B (en) * | 2019-07-19 | 2022-04-29 | 江阴市建鑫金属有限公司 | Method for testing fatigue strength of steel bar welded mesh |
| CN112317994B (en) * | 2020-01-08 | 2022-08-30 | 沈阳和研科技有限公司 | Water tank welding process method of dicing saw |
| CN117408122B (en) * | 2023-12-12 | 2024-02-27 | 武创芯研科技(武汉)有限公司 | Solder joint stress analysis method and system for ball grid array package under random vibration working condition |
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