CN107563072B - Finite Element Modeling Method of Weld Nut Based on Automobile Fatigue Simulation - Google Patents

Finite Element Modeling Method of Weld Nut Based on Automobile Fatigue Simulation Download PDF

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CN107563072B
CN107563072B CN201710799957.0A CN201710799957A CN107563072B CN 107563072 B CN107563072 B CN 107563072B CN 201710799957 A CN201710799957 A CN 201710799957A CN 107563072 B CN107563072 B CN 107563072B
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nut
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welding
finite element
bolt
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CN107563072A (en
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李天兵
连志斌
杨涵
徐成民
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SAIC Volkswagen Automotive Co Ltd
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Abstract

本发明揭示了一种基于汽车疲劳仿真的焊接螺母有限元建摸方法,包括下述的步骤:焊接螺母建模步骤,通过布点和投射,建立焊接螺母和母材的实体单元网格;焊接螺母与母材连接面的建模步骤,对焊线以及焊接螺母和母材之间的接触建模;螺栓建模步骤,对与焊接螺母配合的螺栓建模;焊接螺母与螺栓装配的建模步骤,对螺栓与焊接螺母的连接的建模并设置螺栓预紧力;有限元计算步骤,将所建立的模型移入疲劳有限元计算模型中,通过有限元程序的仿真,得到有限元焊接螺母的受力模式。本发明既考虑了焊接处的连接结构,又考虑了螺母对板材的接触效应。能够准确模拟焊接螺母在疲劳仿真中的变形行为,进而得到准确的板材应力分布。

Figure 201710799957

The invention discloses a welding nut finite element modeling method based on automobile fatigue simulation. Modeling steps for connecting surfaces to base metal, butt weld lines and contact between weld nut and base metal; Bolt modeling steps, Modeling bolts mated to weld nuts; Modeling steps for weld nut and bolt assemblies , model the connection between the bolt and the welding nut and set the bolt pre-tightening force; in the finite element calculation step, move the established model into the fatigue finite element calculation model, and obtain the finite element welding nut through the simulation of the finite element program. force mode. The present invention not only considers the connection structure of the welding place, but also considers the contact effect of the nut on the plate. The deformation behavior of the welding nut in the fatigue simulation can be simulated accurately, and the accurate stress distribution of the plate can be obtained.

Figure 201710799957

Description

Finite element modeling method for weld nut based on automobile fatigue simulation
Technical Field
The invention relates to the field of automobile manufacturing, in particular to a simulation test method in an automobile manufacturing process.
Background
A weld nut is a nut that is adapted to be welded at the outer edge of the nut, and is typically made of a weldable material and is relatively thick and adapted to be welded. During welding, two separated parts are integrated, the metal is melted at high temperature and then mixed together for cooling, and alloy is added in the middle. The interior of the weld nut is generally stronger than the nut under the influence of molecular forces. The welded nut has the advantages of high strength, wide application range and proper thickness, but the connected part is deformed due to high temperature and cannot be disassembled, and some active metals are not suitable for welding by the method, such as aluminum, magnesium and the like, need shielding gas argon arc welding, and require high processing technology and precision.
Finite elements are a numerical technique in mathematics to approximate a solution to the problem of solving partial differential equations. When solving, the whole problem area is decomposed, each subarea becomes a basic unit, and the basic unit is called a finite element. The finite element method is suitable for computer programming, along with the development of computer hardware, the finite element method can grade the structural performance of parts and the whole vehicle as early as possible, find weak links of design quickly, put forward optimization and improvement suggestions, reduce the number of experimental sample vehicles and the number of tests, shorten the development time, reduce the development cost and improve the maturity of products.
No engineering personnel have studied the method of simulating weld nuts in finite element simulation to date. Even the existing finite element models of the welding nuts are established according to the mechanical properties of the bolts and the nuts and neglect the contact effect of the nuts or the bolts on the plates, the modeling modes of the welding nuts are roughly divided into two types, one type is to neglect the welding relation of the bolts and the nuts and directly connect the plates by rigid units. The other type is that the bolt is modeled physically, but the welding form of the nut and the contact relation between the nut and the plate are ignored. For automobile fatigue simulation, a region with large local stress is often required to be analyzed, a traditional modeling mode usually only can accurately analyze the stress outside a bolt connection region due to neglecting an actual stress mechanism of the connection region, the stress analysis of the connection is very inaccurate, and a large number of experiments prove that the connection region of a welding nut happens to be a common place where cracking occurs, so that a finite element modeling mode for the welding nut in the prior art has a remarkable defect.
Disclosure of Invention
The invention aims to provide a welded nut finite element modeling method based on automobile fatigue simulation, which comprises the following steps:
a welded nut modeling step, namely establishing a solid unit grid of the welded nut and a base metal through point arrangement and projection;
modeling a welding nut and base metal connecting surface, namely modeling a welding line and contact between the welding nut and the base metal;
a bolt modeling step, namely modeling a bolt matched with the welding nut;
a modeling step of assembling the welded nut and the bolt, wherein the connection between the bolt and the welded nut is modeled and the pretightening force of the bolt is set;
and (4) finite element calculation, namely moving the established model into a fatigue finite element calculation model, and obtaining a stress mode of the finite element welded nut through simulation of a finite element program.
In one embodiment, the weld nut modeling step comprises:
a point distribution step, namely uniformly distributing points on the lap joint surface of the welding nut by using a geometric processing module, distributing a welding area by using hard points according to the actual length and position of a welding line, and then projecting the hard points onto the surface of the base metal to enable the welding nut and the nodes generated on the surface of the base metal to be in one-to-one correspondence;
a welded nut grid generating step, namely dividing the outer surface of the welded nut by utilizing a shell unit, defining the welded nut as a closed shell as a body, and then generating a hexahedral solid unit grid by using a projection method;
a parent material grid generating step, wherein a hexahedron solid unit grid is generated by extracting from the middle surface of a parent material and using an offset method;
and a material parameter setting step of giving material parameters to the weld nut and the base material.
In one embodiment, the weld nut in the weld nut generating step is a quadrangular unit within the range of the base. In the parent material mesh generation step, the parent material is a quadrangular unit in the range of the base.
In one embodiment, the parameters set in the material parameter setting step include: density, modulus of elasticity, poisson's ratio.
In one embodiment, the step of modeling the weld nut to parent material joint face comprises:
a welding wire modeling step, namely bonding nodes in the lapping surface of a welding nut and a base metal in a welding wire area in a one-to-one correspondence manner to generate a common node unit;
and a contact modeling step, namely modeling the contact by taking a region except a welding seam on the lap joint surface of the welding nut and the base material as a contact region based on finite element analysis.
In one embodiment, in the contact modeling step, the contact area on the base material is used as a slave surface, the contact area on the weld nut is used as a main surface, the contact mode is surface-surface contact, the preset friction coefficient is provided, and the contact type is sport contact.
In one embodiment, the bolt modeling step models the bolt with a one-dimensional beam element, and the parameters of the interface and the material are set according to the model of the bolt.
In one embodiment, the step of modeling the weld nut and bolt assembly comprises:
modeling connection of a bolt and a welding nut, grabbing all nodes in an area of an internal thread of the welding nut by using a rigid unit to generate a first rigid unit, connecting a mass center point of the first rigid unit with one end of a one-dimensional beam unit, grabbing nodes in a range compressed by a nut of the bolt on the surface of a base material by using the rigid unit to generate a second rigid unit, and connecting the mass center of the second rigid unit with the other end of the one-dimensional beam unit;
and setting bolt pretightening force, and setting the pretightening force on the one-dimensional beam unit according to the bolt grade by using finite element analysis.
In one embodiment, the rigid connection elements are compared as simulations in the finite element calculation step.
Aiming at the defects of the prior art, the finite element modeling method of the welding nut based on the automobile fatigue simulation not only considers the connection structure of the welding position, but also considers the contact effect of the nut on the plate. The method can accurately simulate the deformation behavior of the welding nut in fatigue simulation, so as to obtain accurate plate stress distribution, is quick and effective, and is convenient for engineering technicians to master.
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The above and other features, properties and advantages of the present invention will become more apparent from the following description of the embodiments with reference to the accompanying drawings in which like reference numerals denote like features throughout the several views, wherein:
FIG. 1 discloses a flow chart of a weld nut finite element modeling method based on automotive fatigue simulation according to an embodiment of the present invention.
Fig. 2 discloses a schematic view of the weld nut.
Fig. 3 discloses a schematic view of the connection structure of the weld nut, the bolt and the base material.
Fig. 4 discloses a schematic diagram of weld nut "common node + contact" modeling.
Fig. 5 discloses a schematic diagram of the connection modeling of the weld nut, bolt and parent material.
Detailed Description
Referring to FIG. 1, FIG. 1 discloses a flow chart of a weld nut finite element modeling method based on automobile fatigue simulation according to an embodiment of the present invention. The weld nut finite element modeling method of the present invention is described below in connection with a specific example.
The example simulates the cracking of a tail pipe bracket with a welded nut in a certain development vehicle type in a fatigue test. The weld nut has a diameter of 18mm, the bolt is M8, class 6.8, and has three equal weld lines at its edges, as shown in fig. 2, and fig. 2 shows a schematic view of the weld nut of this example. The weight of the exhaust pipe and the muffler is 13.5 kg, the thickness of the tail pipe support is 1.5mm, the material is H260, the yield limit is 272MPa, the connection structure of the welding nut, the bolt and the base material in the example is shown in FIG. 3, and FIG. 3 discloses a schematic connection structure of the welding nut, the bolt and the base material. The tail pipe bracket for lifting the muffler and the adjacent part of the body-in-white were used as calculation models, and the load was set to be 4 times 540N of the weight of the muffler. The boundary condition is that the interception position of the part is restricted with six degrees of freedom. The analysis software is Abaqus, the bolt pretightening force is loaded in the first step, and 4 times of the weight of the silencer is loaded in the second step to be used as the external load. The finite element modeling process of the weld nut, namely the finite element modeling method of the weld nut based on the automobile fatigue simulation, is described in detail as follows, and the method comprises the following steps:
101. and a welded nut modeling step, namely establishing a solid unit grid of the welded nut and the base metal through point distribution and projection. In one embodiment, the weld nut modeling step 101 includes several substeps:
and a point distribution step, namely uniformly distributing points on the lap joint surface of the welded nut by using a geometric processing module, referring to engineering technical drawings, distributing a welding area by using hard points according to the actual length and position of a welding line, and then projecting the hard points onto the surface of the base metal, so that the welded nut and the nodes generated on the surface of the base metal are in one-to-one correspondence.
And a welded nut grid generating step of dividing the outer surface of the welded nut by using shell units, wherein the welded nut is a quadrilateral unit in the range of a base, the welded nut is a closed shell, the closed shell is defined as a body, and then a hexahedral solid unit grid is generated by using a projection (map) method.
And a parent material mesh generation step of extracting the parent material mesh from the middle surface of the parent material, and generating a hexahedral solid cell mesh by using an offset (offset) method, wherein the parent material mesh is a quadrilateral cell within the range of the base.
And a material parameter setting step of giving material parameters to the weld nut and the base material. In one embodiment, the parameters set in the material parameter setting step include: density, modulus of elasticity, poisson's ratio, and the like.
102. And modeling the connection surface of the welding nut and the base metal, namely modeling the welding line and the contact between the welding nut and the base metal. In one embodiment, the step 102 of modeling the weld nut to parent material joint face comprises:
and a welding line modeling step, namely bonding the nodes in the lapping surface of the welding nut and the base metal in the area where the welding line is positioned in a one-to-one correspondence mode to generate a common node unit.
And a contact modeling step, based on finite element analysis, taking a region except a welding seam on the faying surface of the welding nut and the base material as a contact region, and modeling the contact, wherein the contact region on the base material is taken as a slave surface, the contact region on the welding nut is taken as a main surface, the contact mode is surface-surface contact, the preset friction coefficient is realized, and the contact type is kinematic contact. In this example, the friction coefficient was set to 0.2.
The modeling step 102 of welding the connection surface of the nut and the base material realizes a mode of 'common node + contact' modeling, and referring to fig. 4, fig. 4 discloses a schematic diagram of 'common node + contact' modeling of the welded nut.
103. And a bolt modeling step, namely modeling the bolt matched with the welding nut. In the bolt modeling step 103, the bolt is modeled by a one-dimensional beam unit, and parameters of an interface and a material are set according to the model of the bolt.
104. And a modeling step of assembling the welded nut and the bolt, wherein the connection between the bolt and the welded nut is modeled and the pretightening force of the bolt is set. In one embodiment, the modeling 104 of the weld nut and bolt assembly includes:
modeling of connection of the bolt and the welding nut, grabbing all nodes in an area of an internal thread of the welding nut by using a rigid unit to generate a first rigid unit, connecting a mass center point of the first rigid unit with one end of a one-dimensional beam unit, grabbing nodes in a range compressed by a nut of the bolt on the surface of a base material by using the rigid unit to generate a second rigid unit, and connecting the mass center of the second rigid unit with the other end of the one-dimensional beam unit, wherein a schematic diagram for modeling of rigid connection of the welding nut, the bolt and the base material is disclosed in fig. 5, which is shown in fig. 5. In fig. 5, the first rigid unit and the second rigid unit are each represented by a rigid unit icon, and the first rigid unit, the second rigid unit, and the one-dimensional beam unit all belong to the modeling unit.
And setting bolt pretightening force, and setting the pretightening force on the one-dimensional beam unit according to the bolt grade by using finite element analysis. The bolt class can be referred to the instructions of the machine manual, in this example, the M8, class 6.8 bolt pretension is 17000N, as specified in the machine manual, using finite element analysis software, and the pretension is applied to the one-dimensional beam element.
105. And (4) finite element calculation, namely moving the established model into a fatigue finite element calculation model, and obtaining a stress mode of the finite element welded nut through simulation of a finite element program. In one embodiment, the rigid connection elements are compared as simulations in the finite element calculation step. In the finite element calculation step 105, the established weld nut model is moved into the finite element calculation model, and meanwhile, for the purpose of comparing simulation results well, rigid connection units which are most commonly used in automobile simulation calculation at present are introduced as models for simulation comparison in the example. And finally, a stress distribution result on the tail pipe support can be obtained through simulation of a commercial finite element calculation program Abaqus, and the stress distribution result is compared with a test result. By comparison, the stress distribution condition obtained by applying the calculation model of the technology is good in test goodness of fit, the maximum stress is generated at the welding edge of the welding nut, a triangle formed by the stress distribution in the stress distribution diagram is consistent with the shape of cracking in the test, and the maximum stress is 275MPa and is slightly larger than the yield strength of the base metal, namely 272MPa, so that the support is at risk of fatigue cracking. The result is obtained by using a conventional rigid connection calculation model, the rigidity of the welding seam is greatly increased by rigid connection between the nut and the base material, so that the stress at the original weak welding line is obviously reduced, the maximum stress is only 0.9MPa and is far less than the yield strength of the base material, the fatigue cracking risk is avoided, and the stress distribution pattern is also inconsistent with the cracking form of the test.
Because the stress distribution condition is the most key and direct basis and standard in the automobile fatigue simulation calculation, the 'common node + contact' modeling method provides a quick and correct finite element model for welding the nut, so that an automobile structure designer can be assisted to quickly and accurately evaluate the fatigue performance of the base material, and reliable CAE analysis support is provided for further optimization and improvement of parts.
The invention has the following advantages:
1. the modeling process is simple: the welded nut model can be transplanted to any automobile fatigue simulation model only by simple common-node bonding, contact pair setting and pre-tightening force applying material attribute setting, and parameters can be adjusted.
2. The simulation precision is high: the built welding nut model comprehensively considers the welding seam and contact between the nut and the plate, and the bolt applies pretightening force, so that the stress condition of the plate on the welding nut side is completely consistent with the real condition, and the mechanical behavior and the deformation mode of the welding seam under the action of fatigue load can be correctly simulated.
3. The simulation efficiency is high: solid modeling is adopted for the weld nut of the primary analysis and the base material on the same side, and a beam unit is adopted for the bolt of the secondary analysis.
4. The simulation stability is good: the weld nuts are in one-to-one correspondence with grids on the surface of the base metal, so that nodes on the main surface and the secondary surface which are in contact are completely corresponding, the problem of non-convergence in implicit calculation is solved, and the phenomena of unstable resolving such as shooting points, negative volumes and the like which often occur in a shell unit and a solid unit cannot occur in the weld nut model.
Aiming at the defects of the prior art, the finite element modeling method of the welding nut based on the automobile fatigue simulation not only considers the connection structure of the welding position, but also considers the contact effect of the nut on the plate. The method can accurately simulate the deformation behavior of the welding nut in fatigue simulation, so as to obtain accurate plate stress distribution, is quick and effective, and is convenient for engineering technicians to master.
The embodiments described above are provided to enable persons skilled in the art to make or use the invention and that modifications or variations can be made to the embodiments described above by persons skilled in the art without departing from the inventive concept of the present invention, so that the scope of protection of the present invention is not limited by the embodiments described above but should be accorded the widest scope consistent with the innovative features set forth in the claims.

Claims (8)

1.一种基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,包括:1. a welding nut finite element modeling method based on automobile fatigue simulation, is characterized in that, comprises: 焊接螺母建模步骤,通过布点和投射,建立焊接螺母和母材的实体单元网格,该焊接螺母建模步骤包括:The welding nut modeling step, through point layout and projection, establishes the solid element mesh of the welding nut and the base metal. The welding nut modeling step includes: 布点步骤,利用几何处理模块在焊接螺母的搭接面均匀布点,按焊缝的实际长度和位置,用硬点布置焊接区域,然后将所述硬点投射到母材表面上,使得焊接螺母和母材表面所生成节点的一一对应;In the point layout step, the geometric processing module is used to evenly distribute points on the lap surface of the weld nut, and the welding area is arranged with hard points according to the actual length and position of the weld, and then the hard points are projected onto the surface of the base metal, so that the weld nut and the One-to-one correspondence of nodes generated on the surface of the base metal; 焊接螺母网格生成步骤,利用壳单元划分出焊接螺母的外表面,焊接螺母为封闭的壳,将该封闭的壳定义为体,然后用投射的方法生成六面体实体单元网格;In the welding nut mesh generation step, the outer surface of the welding nut is divided by the shell element, the welding nut is a closed shell, and the closed shell is defined as a volume, and then the hexahedral solid element mesh is generated by the projection method; 母材网格生成步骤,从母材的中面抽出,用偏移的方法,生成六面体实体单元网格;The base metal mesh generation step is to extract from the middle surface of the base metal, and use the offset method to generate a hexahedral solid element mesh; 材料参数设置步骤,给焊接螺母和母材赋予材料参数;Material parameter setting step, assign material parameters to the weld nut and base metal; 焊接螺母与母材连接面的建模步骤,对焊线以及焊接螺母和母材之间的接触建模;Modeling steps for the connection surface of the weld nut and the base metal, modeling the weld wire and the contact between the weld nut and the base metal; 螺栓建模步骤,对与焊接螺母配合的螺栓建模;Bolt modeling step, modeling bolts that fit with weld nuts; 焊接螺母与螺栓装配的建模步骤,对螺栓与焊接螺母的连接的建模并设置螺栓预紧力;The modeling steps of welding nut and bolt assembly, modeling the connection between bolt and welding nut and setting the bolt preload; 有限元计算步骤,将所建立的模型移入疲劳有限元计算模型中,通过有限元程序的仿真,得到有限元焊接螺母的受力模式。In the finite element calculation step, the established model is moved into the fatigue finite element calculation model, and the stress mode of the finite element welding nut is obtained through the simulation of the finite element program. 2.如权利要求1所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,2. the welding nut finite element modeling method based on automobile fatigue simulation as claimed in claim 1, is characterized in that, 所述焊接螺母生成步骤中焊接螺母在基础的范围内是四边形单元;In the welding nut generating step, the welding nut is a quadrilateral element within the scope of the foundation; 所述母材网格生成步骤中母材在基础的范围内是四边形单元。In the step of generating the base material mesh, the base material is a quadrilateral element within the range of the foundation. 3.如权利要求1所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述材料参数设置步骤中设置的参数包括:密度,弹性模量,泊松比。3 . The finite element modeling method for welding nuts based on automobile fatigue simulation according to claim 1 , wherein the parameters set in the material parameter setting step include: density, elastic modulus, and Poisson's ratio. 4 . 4.如权利要求1所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述焊接螺母与母材连接面的建模步骤包括:4. The welding nut finite element modeling method based on automobile fatigue simulation according to claim 1, wherein the modeling step of the welding nut and the base metal connection surface comprises: 焊线建模步骤,将焊线所在区域内,焊接螺母和母材的搭接面内的节点一一对应地粘结起来,生成共节点单元;In the welding wire modeling step, in the area where the welding wire is located, the nodes in the overlapping surface of the welding nut and the base metal are bonded one by one to generate a common node element; 接触建模步骤,基于有限元分析,将焊接螺母与母材的搭接面上除焊缝的区域作为接触区域,对接触建模。In the contact modeling step, based on finite element analysis, the contact area is modeled by taking the area on the lap surface of the weld nut and the base metal except for the weld seam as the contact area. 5.如权利要求4所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述接触建模步骤中,母材上的接触区域作为 从面,焊接螺母上的接触区域作为主面,接触方式为面-面接触,具有预设的摩擦系数,接触类型为运动型接触。5. The finite element modeling method for welding nut based on automobile fatigue simulation according to claim 4, wherein in the contact modeling step, the contact area on the base metal is used as the slave surface, and the contact area on the welding nut is As the main surface, the contact method is surface-to-surface contact, with a preset friction coefficient, and the contact type is kinematic contact. 6.如权利要求1所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述螺栓建模步骤中螺栓由一维梁单元建模,按螺栓的型号设置界面和材料的参数。6. the welding nut finite element modeling method based on automobile fatigue simulation as claimed in claim 1 is characterized in that, in the described bolt modeling step, the bolt is modeled by one-dimensional beam element, and the interface and material are set according to the model of the bolt parameter. 7.如权利要求6所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述焊接螺母与螺栓装配的建模步骤包括:7. The welding nut finite element modeling method based on automobile fatigue simulation as claimed in claim 6, is characterized in that, the modeling step of described welding nut and bolt assembly comprises: 螺栓与焊接螺母的连接的建模,焊接螺母内螺纹的区域的所有节点用刚性单元抓取,生成第一刚性单元,将第一刚性单元的质心点连接所述一维梁单元的一端,再用刚性单元将母材表面上被螺栓的螺帽压紧的范围内的节点抓取,生成第二刚性单元,将第二刚性单元的质心连接所述一维梁单元的另一端;For the modeling of the connection between the bolt and the welding nut, all nodes in the area of the inner thread of the welding nut are grabbed with rigid elements to generate a first rigid element, and the center of mass of the first rigid element is connected to one end of the one-dimensional beam element, and then Grab the nodes on the surface of the base material within the range compressed by the nut of the bolt with the rigid element, generate a second rigid element, and connect the center of mass of the second rigid element to the other end of the one-dimensional beam element; 设置螺栓预紧力,利用有限元分析,按照螺栓等级在所述一维梁单元上设置预紧力。Set the bolt preload, and use finite element analysis to set the preload on the one-dimensional beam element according to the bolt grade. 8.如权利要求1所述的基于汽车疲劳仿真的焊接螺母有限元建摸方法,其特征在于,所述有限元计算步骤中将刚性连接单元作为仿真对比。8 . The finite element modeling method for welding nuts based on automobile fatigue simulation according to claim 1 , wherein, in the finite element calculation step, rigid connection elements are used as simulation comparisons. 9 .
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