CN106980742B - Load projection mapping method for introducing punch forming information into finite element simulation model - Google Patents
Load projection mapping method for introducing punch forming information into finite element simulation model Download PDFInfo
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Abstract
The invention discloses a load projection mapping method for introducing punch forming information into a finite element simulation model, which comprises the following steps: mapping node force information of a sheet material in stamping forming on a die profile grid in a two-time positioning projection manner; load information on the grid of the molded surface of the die is transferred to the tetrahedral units of the die, so that the node acting force of the plate is directly applied to the die to replace the action of the plate on the die. The method realizes the transmission of force between the plate and the die in the punch forming, has important theoretical guiding significance and application value for the structural analysis of the automobile punch forming die, belongs to the technical field of automobiles, solves the problem of how to quickly and accurately project and map the plate punch forming information to a finite element simulation model in the prior art, and realizes the load projection mapping among the acting forces of different grid model nodes.
Description
Technical Field
The invention belongs to the technical field of punch forming, and particularly relates to a load projection mapping method for introducing punch forming information into a finite element simulation model.
Background
With the increasing importance on the aspects of environmental protection, safety, comfort and the like of automobiles, the light weight of automobiles gradually becomes a new trend of the development of the automobile industry. However, the demand for weight reduction has increased the performance of steel sheet materials for vehicle bodies, and high-strength steel sheets have been widely used for vehicle bodies. However, the application of high strength steel sheets poses a series of problems to press production: the formability of the high-strength steel plate is poor, the resilience is serious, the rigidity of the stamping die is insufficient, the design problem is more and more complicated, the design parameters are increased, the mounting, debugging and modifying of the stamping die are difficult, the production progress is influenced, and the like. The design criteria and specifications of the traditional low-strength steel plate stamping die can not meet the design requirements of the high-strength steel plate stamping die any more. The size and the thickness of the die are simply increased, the die material with higher hardness is selected, the cost of the die material and the energy consumption in production are increased, and the safety factor of the die cannot be improved sometimes. Therefore, aiming at the stamping stress characteristics of the high-strength steel plate, a quantitative analysis method is urgently needed for carrying out strength and rigidity check, service life prediction and further structure optimization analysis on the stamping die and establishing a new die structure form, standard and fatigue life evaluation standard.
The traditional mold structure design method is mainly characterized in that a designer forms a design according to the experience of mold enterprise designers and the previous similar mold structure, the quality of the mold structure design is evaluated by lacking a theoretical basis, and the influence on the forming caused by the analysis of the mold structure and the deformation of the mold is little concerned. Some scholars at home and abroad use a finite element analysis technology to study the structural analysis aspect of the stamping die, and the study methods of the scholars can provide reference for the optimization design of the stamping die structure. Becchio et al first analyzed the stress of the press die by using a finite element analysis method, analyzed the stress and deformation distribution of the whole drawing die, and listed some applications of the press die structure analysis, and Keum et al, korea analyzed the elastic deformation of the die and the press by using a finite element analysis technique, and studied the influence of the elastic deformation of the die on the formability of the press part by coupling forming and structure analysis. In China, the blank holder stress condition of a stamping die is obtained through tests by Sun Intelligence development and the like of automobile engineering research institutes of Shanghai automobile industry (group) company, the blank holder stress distribution condition is obtained through numerical simulation, and the result shows that the simulated stress distribution trend is more consistent with the result obtained through the tests. The Liedich of university in Hunan has studied a grid variable mapping algorithm for automobile collision simulation, and it is considered that in the automobile collision simulation analysis, the influence of the thickness change of the sheet material after the part is stamped, the hardening of the material and the residual stress on the simulation result should be considered; the impact research of the impact resistance of the stamping forming history on the typical structure of the vehicle body is researched by Zengpeng and Zhuping of Shanghai transportation university, the formability research of the typical hat-shaped structure of the vehicle body is carried out by adopting a one-step forming method based on the plastic total quantity theory, and the impact of the forming history on the crash resistance of the hat-shaped structure is analyzed through simulation and test comparison. The Huping of Jilin university and the like adopt an independently developed efficient and rapid inverse forming finite element analysis method and a grid mapping technology, and provide a fine simulation analysis method for automobile bodies and parts, which introduces process factors, ensures a design period and improves collision simulation precision. However, the application of the grid variable load mapping method in the analysis of the mold structure is relatively few researchers.
The method has the advantages that the method is very important in the aspect of the current situation that the automobile stamping die is competitive, the design period of the product is shortened, the design quality is improved, and the die cost is reduced. Therefore, a new calculation method is urgently needed to be introduced in the structural design process of the automobile stamping die, the analysis precision of a complex structure is improved, and the optimal design of structural parameters is further realized. Many scholars research the calculation method, find algorithms with high calculation accuracy and efficiency, have achieved a lot of achievements, but still have many problems and are worthy of further exploration.
Disclosure of Invention
The invention provides a load projection mapping method for introducing punch forming information into a finite element simulation model, which aims to solve the problem of how to quickly and accurately transmit the punch forming information of a plate to the finite element simulation model in the prior art and realize transmission between node acting forces of different grid models, thereby achieving the purposes of improving the finite element analysis precision of a die structure, reducing the model solving scale and optimizing the die structure.
In order to solve the technical problem, the load projection mapping method for introducing punch forming information into a finite element simulation model provided by the invention comprises the following steps:
(1) extracting sheet material node information, namely extracting a product profile according to a product digifax provided by a product department, guiding the product profile into sheet material forming analysis software to carry out forming analysis on the sheet material, and extracting the sheet material node information from an analysis result;
(2) extracting the grid node information of the mould profile, establishing a process profile according to the plate forming analysis result, establishing a mould CAD three-dimensional model according to the process profile, extracting the profile of the mould CAD three-dimensional model, and guiding the profile of the mould CAD three-dimensional model into Hyperworks for grid division to obtain the profile grid node information of the mould CAD three-dimensional model;
(3) mapping node force information of a sheet material in stamping forming to die profile grid nodes through programming load to obtain die profile grid node information after load mapping;
(4) and (4) importing the grid node information of the mould profile after load mapping obtained in the step (3) into Hyperworks, establishing a mould finite element model by taking the grid node force of the mould profile after load mapping as a force boundary condition, and analyzing the mould structure finite element.
Further, the load mapping method in the step (3) comprises the following steps:
step 2, reading in the grid node information of the molded surface of the mold by adopting an ifstream file mode;
step 5, mapping the load force on the node O to the corresponding mould profile grid node by utilizing an interpolation shape function;
step 6, repeating the steps until all the load forces on all the nodes in the sheet material node information are mapped to the grid nodes of the molded surface of the mold;
and Step 7, exporting the molded surface grid node information of the mold after load mapping by adopting an OFFLOOUtFile mode.
Further, the plate forming analysis software in the step (1) refers to commercial plate forming analysis software Autoform, the product needs to be analyzed in the Autoform well, and the analysis result cannot be error or warning.
Further, the simplification of the CAD three-dimensional model of the die in the step (2) does not influence the overall rigidity of the die.
Further, the specific steps of local positioning in Step 4 include:
a. taking the node of the molded surface grid of the mold determined by global positioning in Step 3 as a coordinate origin, and taking two edges of a certain triangular unit A taking the coordinate origin as the node in the molded surface grid of the mold as coordinate axes to establish a local coordinate system;
b. if the projection point of the node O is in the triangular unit A, the corresponding grid unit of the node O in the mould profile grid is the triangular unit A; if the projection point of the node O is not in the triangular unit A, establishing a local coordinate system by taking the origin of coordinates as two edges of another triangular unit of the node in the mold profile grid as coordinate axes, and judging whether the projection of the node O is in the selected triangular unit again until finding the corresponding grid unit of the node O in the mold profile grid.
According to the invention, through accurate positioning between two sets of different grid units, a corresponding relation is established between the stamped sheet metal grid unit and the die profile grid unit, a relation model of load mapping between the forming force on the sheet metal unit node and the die profile grid node is established, and the sheet metal forming force is transmitted to the die profile more accurately, so that the simulation calculation precision is improved; the method is applied to analysis of the die structure, the load borne by each part of the die can be accurately calculated, structural analysis models such as strength and fatigue can be better met, and the die is light.
Compared with the prior art, the method has the following advantages:
1. the forming force in the sheet forming numerical analysis is accurately transmitted to the grid nodes of the molded surface of the die to be used as the boundary condition of the die structure analysis, the structure optimization analysis is carried out on the die, the structure of the bearing matrix of the die can be reasonably improved, and the purpose of meeting the requirement on rigidity and strength and realizing light weight of the die matrix is achieved.
2. The sheet forming numerical simulation and the die structure analysis numerical simulation adopt two sets of grid expressions, the grid division can be reasonably carried out according to the requirements of different processes on the grid, and the contradiction between the solving precision and the model scale is well solved; the interaction force between the deformed plate and the mould replaces the complex contact coupling effect between the deformed plate and the mould, on the premise of reflecting the stress of the mould more truly, the complexity of the problem is greatly simplified, the solving scale of the model is obviously reduced, and the method can be popularized to other application fields.
In conclusion, the load mapping method for introducing the punch forming information into the finite element simulation model realizes the force transmission between the plate and the die, and has important theoretical guiding significance and application value for improving the structural analysis of the automobile punch forming die.
Drawings
FIG. 1 is a schematic flow diagram of the present invention;
FIG. 2 is a schematic three-dimensional modeling structure of a rear longitudinal beam in an embodiment of the invention;
FIG. 3 is a load map pattern;
FIG. 4 is a global positioning map;
FIG. 5 is a partial alignment view;
FIG. 6 is a graph of interpolation calculations for a load;
fig. 7 is a flowchart of a load mapping method.
Detailed Description
The invention will be further described with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1-7, the load projection mapping method for introducing stamping forming information into a finite element simulation model provided by the invention comprises the following steps:
(1) extracting the node information of the plate: taking Autoform as a numerical simulation platform, extracting product profiles (upper and lower profile references) according to product figures and expressions provided by a product department, introducing the product profiles into the Autoform to carry out formability analysis on a plate material, judging whether the product has formability problems (such as tension crack, wrinkling and the like) according to an analysis result, if the product has the formability problems, proposing a product change requirement on the product, and then analyzing the new product according to feedback until no formability problem exists, and if the product does not have the formability problems, proposing no change requirement on the product; obtaining a stamping model without forming defects, and extracting sheet material node information (node coordinates, units and node force) from an analysis result; outputting the plate node information in an af format if the analysis result cannot generate error or warning, and opening the af file in Excel to store the af file as a dat format file as a plate node information source file 1;
(2) extracting the information of the grid nodes on the molded surface of the mold: establishing a process profile according to a plate forming result in Autoform, establishing a die CAD three-dimensional model according to the process profile, and reasonably simplifying the die CAD three-dimensional model, wherein the simplification of the die CAD three-dimensional model does not influence the overall rigidity of the die; extracting a molded surface of a CAD (computer-aided design) three-dimensional model of the mould, introducing the molded surface of the CAD three-dimensional model of the mould into Hyperworks for grid division, acquiring grid node information (node coordinates and units) of the molded surface of the CAD three-dimensional model of the mould, and storing the grid node information of the molded surface of the CAD three-dimensional model of the mould as a dat file as a grid information source file 2 of the molded surface of the mould;
(3) mapping node force information of a plate material in stamping forming to a die profile grid node through programming load:
step 2, reading a die profile grid information source file 2 in an ifstream file mode;
step 5, mapping the load force on the node O to the corresponding triangular unit node of the mould profile mesh by using an interpolation shape function to realize the transfer of the load variable value between the mesh models;
step 6, repeating the steps until all the load forces on all the nodes in the sheet material node information are mapped onto the die profile grid nodes, when the number of the sheet material nodes after sheet material stamping simulation is larger than that of the die profile grid nodes, a plurality of sheet material nodes possibly correspond to the same die profile triangular grid, and at the moment, averaging the load forces on the die profile grid nodes after mapping;
(4) reading in a load output file 3 in Hyperworks, establishing a die finite element model by taking the grid node force of the die molded surface after load mapping as a force boundary condition, and performing structural analysis and post-processing on the die by using an Optistruct module in Hyperworks.
As shown in fig. 5, the specific steps of local positioning in Step 4 include:
a. taking the node of the molded surface grid of the mold determined by global positioning in Step 3 as a coordinate origin, and taking two edges of a certain triangular unit A taking the coordinate origin as the node in the molded surface grid of the mold as coordinate axes to establish a local coordinate system;
b. if the projection point of the stamping model node O is in the triangular unit A, the corresponding grid unit of the stamping model node O on the molded surface of the die is the triangular unit A; if the projection point of the point O is not in the triangular unit A, establishing a local coordinate system by taking the origin of coordinates as two sides of another triangular unit of the node in the grid of the mold surface of the mold as coordinate axes, and judging whether the projection of the node O of the stamping model is in the selected triangular unit again until finding the grid unit corresponding to the node O of the stamping model on the mold surface of the mold.
The following will describe the mapping method in detail with a certain longitudinal beam of the automobile as the object of study:
FIG. 2 is a schematic diagram of a three-dimensional modeling structure of a certain longitudinal beam, and a local shape A is selected according to the geometrical shape of a rear longitudinal beam for analysis;
as shown in fig. 4, the idea of central projection is adopted to perform global positioning, that is, a certain node O in the sheet node information is taken as a central point, a given threshold length is taken as a radius r, and an included angle θ (θ <90 °) with the stamping direction is projected, then global search is performed on each node of the die profile grid, whether each node of the die profile grid is in a projection area is judged, a unit of the die profile node structure in the projection area is a unit range of local positioning, vector product sizes of each node of the die profile grid and the node O in the projection area and a unit vector of the stamping direction are compared, and a die profile grid node with the minimum vector product in the projection area is determined as a coordinate origin of local positioning; in fig. 4, four nodes M6, M7, M10 and M11 are in a projection region, the magnitude of the vector product of the OM6, OM7, OM10 and OM11 vectors and the punching direction unit vector e0 is compared, the vector product of the OM6 and the punching direction unit vector e0 is the minimum in the figure, that is, the node M6 is a local coordinate origin;
as shown in fig. 5, local positioning is performed on nodes of a mold profile mesh by using a projection idea of points on a plane, a triangle unit E8 of the mold profile mesh is analyzed, an M6 node determined by global positioning is used as an origin of a local coordinate system, an edge M6M11 and an edge M6M7 are respectively used as u and v coordinate axes to establish a local coordinate system, and a triangle τ with a vertex of { M6, M7, M11} can be expressed as a parameter form τ (s, t) ═ M6+ su1+ tv2, where u1 ═ M11-M6, v2 ═ M7-M6, (s, t) ∈ D { (s, t) | s ∈ [0,1], t ∈ [0,1], s + t ≦ 1}, where s, t is a parameter, which is equivalent to x, y, and u1, v2 are vectors; judging the projection point of the node O in the plane M6M7M11 in FIG. 4, if the projection point of the node O is in the triangle unit M6M7M11, the grid unit corresponding to the node O on the mold profile grid is E8, if the projection point of the node O is not in the triangle unit E8, the M6 node is used as the origin of the local coordinate system to reestablish the local coordinate system, and the projections of the node O in the other units E1, E4, E5, E7 and E11 are judged again until the corresponding grid unit of the node O in the mold profile grid is found;
as shown in fig. 6, an interpolation shape function is adopted to map the load force on the nodes of the triangular unit for forming the plate material to the triangular units of the mesh of the mould profile; the interpolation shape functions of three nodes M6, M7 and M11 of a triangular grid in the die profile grid are respectively N1, N2 and N3, wherein:
n2 ═ s 1;
N1＝1–N2–N3＝1-s1–t1
wherein e1, e2 and e3 represent vectors, s1 and t1 are parameters, (s1, t1) ∈ D { (s1, t1) | s1 ∈ [0,1], t1 ∈ [0,1], s1+ t1 ≦ 1 };
therefore, the interpolation shape function is the coordinate value of the node O, and after the coordinate of the point closest to the space point in the triangle is obtained, the interpolation function of the point in the corresponding triangle is determined;
setting the load of the load point of the node O in the plate node information under a space global coordinate system as Fo (Fox, Foy, Foz), moving the load to a triangle formed by three nodes M6, M7 and M11 of a certain triangular grid of the die, wherein interpolation shape functions of the moving target point to the three nodes in the triangle are respectively N1, N2 and N3, and the loads interpolated to the three nodes are respectively N1, N2 and N3
P1 ═ P1x, P1y, P1z, P2 ═ P2x, P2y, P2z, P3 ═ P3x, P3y, P3z,
and obtaining the node force mapping of other plate materials in the same way.
The invention researches a new grid variable load projection mapping method aiming at the stamping forming process of a high-strength steel plate, provides a load projection mapping calculation method between two sets of different grid triangular units, and has important theoretical guiding significance and application value for improving the automobile finite element analysis precision and optimizing the design of a die structure.
Claims (5)
1. A load projection mapping method for introducing punch forming information into a finite element simulation model is characterized in that: the method comprises the following steps:
(1) extracting sheet material node information, namely extracting a product profile according to a product digifax provided by a product department, guiding the product profile into sheet material forming analysis software to carry out forming analysis on the sheet material, and extracting the sheet material node information from an analysis result;
(2) extracting the grid node information of the mould profile, establishing a process profile according to the plate forming analysis result, establishing a mould CAD three-dimensional model according to the process profile, extracting the profile of the mould CAD three-dimensional model, and guiding the profile of the mould CAD three-dimensional model into Hyperworks for grid division to obtain the profile grid node information of the mould CAD three-dimensional model;
(3) mapping node force information of a sheet material in stamping forming to die profile grid nodes through programming load to obtain die profile grid node information after load mapping;
(4) importing the grid node information of the mould profile after load mapping obtained in the step (3) into Hyperworks, establishing a mould finite element model by taking the grid node force of the mould profile after load mapping as a force boundary condition, and analyzing the mould structure finite element;
the load mapping in the step (3) is realized by the following steps:
step 1, reading plate node information after plate stamping simulation by adopting an ifstream file mode;
step 2, reading in the grid node information of the molded surface of the mold by adopting an ifstream file mode;
step 3, carrying out global positioning by adopting the central projection idea: taking a certain node O in the plate node information in the step (1) as a central point, giving a threshold length as a radius r and forming an included angle theta with the stamping direction for projection, then carrying out global search on the die profile grid nodes, judging whether each node of the die profile grid is in a projection area or not, wherein a unit constructed by the die profile grid nodes in the projection area is a unit range for local positioning; comparing the vector formed by each node of the die profile grid and the node O in the projection area with the vector product of the unit vector in the stamping direction, and determining the die profile grid node with the minimum vector product in the projection area as the coordinate origin of local positioning;
step 4, locally positioning the grid nodes of the molded surface of the mold by adopting the projection idea of points on a plane, establishing a local coordinate system by using a coordinate origin determined by global positioning, and accurately positioning the nodes O in the sheet material node information in the triangular grid cells corresponding to the nodes O in the grid of the molded surface of the mold;
step 5, mapping the load force on the node O to the corresponding mould profile grid node by utilizing an interpolation shape function;
step 6, repeating the steps until all the load forces on all the nodes in the sheet material node information are mapped to the grid nodes of the molded surface of the mold;
and Step 7, exporting the molded surface grid node information of the mold after load mapping by adopting an OFFLOOUtFile mode.
2. The method of load projection mapping for introducing stamping forming information into a finite element simulation model as claimed in claim 1, wherein: the plate forming analysis software in the step (1) refers to commercial plate forming analysis software Autoform, the product needs to be analyzed in Autoform with a good result, and the analysis result cannot appear error or warming.
3. The method of load projection mapping for introducing stamping forming information into a finite element simulation model as claimed in claim 1, wherein: and (3) simplifying the CAD three-dimensional model of the die in the step (2) without influencing the overall rigidity of the die.
4. The method of load projection mapping for introducing stamping forming information into a finite element simulation model as claimed in claim 1, wherein: the specific steps of local positioning in Step 4 comprise:
a. taking the node of the molded surface grid of the mold determined by global positioning in Step 3 as a coordinate origin, and taking two edges of a certain triangular unit A taking the coordinate origin as the node in the molded surface grid of the mold as coordinate axes to establish a local coordinate system;
b. if the projection point of the node O is in the triangular unit A, the corresponding grid unit of the node O in the mould profile grid is the triangular unit A; if the projection point of the node O is not in the triangular unit A, establishing a local coordinate system by taking the origin of coordinates as two edges of another triangular unit of the node in the mold profile grid as coordinate axes, and judging whether the projection of the node O is in the selected triangular unit again until finding the corresponding grid unit of the node O in the mold profile grid.
5. The method of load projection mapping for introducing stamping forming information into a finite element simulation model as claimed in claim 1, wherein: and (4) carrying out structural analysis and post-treatment on the mould by utilizing an Optistruct module in Hyperworks.
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| CN110837707B (en) * | 2019-11-04 | 2023-06-06 | 南京麦慎数字科技有限公司 | Finite element analysis system, method, computer equipment and storage medium |
| CN113239592B (en) * | 2021-05-19 | 2022-07-01 | 北京航空航天大学 | Hierarchical load decomposition method for simulation application of complex multi-layer structure product |
| CN116933442B (en) * | 2023-08-15 | 2024-02-09 | 广州知元科技有限责任公司 | Stamping process simulation model modeling method and related device |
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