CN108646689B - Virtual production manufacturing method and system based on welding - Google Patents
Virtual production manufacturing method and system based on welding Download PDFInfo
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Abstract
The invention provides a virtual production manufacturing method and a virtual production manufacturing system based on welding, wherein the method comprises the following steps: performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials to obtain the welding parameters and the welding sequence of each welding joint; acquiring a three-dimensional process model and three-dimensional process equipment of a product to be produced according to welding parameters of each welding joint; generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and adjusting each procedure in the welding process model; and performing virtual production manufacturing on the product to be produced according to the adjusted welding flow model. The invention reduces manpower and material resources and shortens the production period of the product to be produced.
Description
Technical Field
The invention belongs to the technical field of computer simulation, and particularly relates to a virtual production manufacturing method and system based on welding.
Background
With the diversification of product requirements, the structural design of products shows explosive growth. The trial production period from new products to batch production is long, and design feedback optimization is delayed. In the face of intense market competition, the shorter the period from design to production and manufacture, the more cost-saving and the easier the market is opened.
In the process of testing or putting into production of the product, a field worktable is occupied to carry out the manufacturing test of the new product. Conventional layout designs use an approximation structure for statistical estimation, which is repeatedly modified to optimize the process flow after the process layout is completed. On the one hand, the occupied area of the field is increased, the field product manufacturing is influenced, the waste of manpower and materials in the trial-manufacturing process is caused, and a large amount of time is spent. On the other hand, the process flow and the manufacturing of the beat are completely dependent on experience, which is not beneficial to accurately master the optimal flow of welding production and manufacturing.
Disclosure of Invention
In order to overcome the problems that the existing welding production manufacturing method is time-consuming and labor-consuming, and the welding process is inaccurate or at least partially solve the problems, the invention provides a virtual production manufacturing method and a virtual production manufacturing system based on welding.
According to a first aspect of the present invention, there is provided a virtual production manufacturing method based on welding, comprising:
performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint;
the method comprises the steps of obtaining welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint;
generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each process in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold;
and performing virtual production manufacturing on the product to be produced according to the adjusted welding process model.
Specifically, before the steps of performing elastoplasticity calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the corresponding thermo-physical performance parameters of a preset welding material, the method further comprises the following steps of:
for any parent material sample, carrying out thermophysical performance test on the parent material sample and a welding material sample corresponding to the parent material sample to obtain a group of thermophysical performance parameters;
constructing a thermophysical property parameter database according to each group of thermophysical property parameters;
and inquiring in the thermophysical performance parameter database according to the base metal and the preset welding material of each welding joint in the product to be produced to obtain a group of thermophysical performance parameters corresponding to the base metal and the preset welding material of each welding joint.
In particular, the thermophysical performance parameters include one or more of elastic modulus, poisson's ratio, shear modulus, tensile strength, and yield strength.
Specifically, the steps of performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint in the product to be produced according to the base metal of each welding joint in the product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint specifically include:
constructing an initial three-dimensional model of a product to be produced based on modeling simulation software and three-dimensional linking software, and determining a welding joint in the initial three-dimensional model;
and performing elastic-plastic calculation on each welding joint based on numerical calculation and optimization software, and simultaneously performing deformation analysis and stress analysis on each welding joint to obtain welding parameters and a welding sequence of each welding joint.
Specifically, the step of obtaining the welding process allowance of each welding joint according to the welding parameters of each welding joint, and generating the three-dimensional process model of the product to be produced according to the welding process allowance of each welding joint specifically includes:
acquiring the post-welding deformation of each welding joint according to the welding parameters of each welding joint;
optimizing the welding joints with welding shrinkage in the initial three-dimensional model of the product to be produced according to the post-welding deformation to obtain the welding process allowance of each welding joint;
and adding the welding process allowance into the initial three-dimensional model of the product to be produced, and generating the three-dimensional process model of the product to be produced.
Specifically, the step of obtaining the tool reverse deformation amount of each welding joint according to the welding parameters of each welding joint and generating the three-dimensional process equipment of the product to be produced according to the welding tool reverse deformation amount of each welding joint specifically includes:
acquiring a deformation position of the initial three-dimensional model according to welding parameters of each welding joint;
generating a mechanical clamping model according to the tool reversible deformation amount of each deformation position;
generating three-dimensional process equipment of the product to be produced according to the mechanical clamping model;
the tool reversible deformation amount comprises boundary constraint points, reverse deformation amount and reverse acting force of each deformation position.
Specifically, the procedures in the welding process model include one or more of assembly, welding, grinding, inspection, and adjustment.
Specifically, the step of adjusting each process in the welding process model until the productivity of the adjusted welding process model is greater than or equal to the preset threshold further includes:
and calculating one or more of welding quality, welding rhythm and welding material quota of each procedure in the adjusted welding process model.
According to a second aspect of the present invention, there is provided a welding-based virtual production manufacturing system, comprising:
the system comprises an acquisition module, a processing module and a control module, wherein the acquisition module is used for performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint;
the generating module is used for acquiring welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of the product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint;
the adjusting module is used for generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each procedure in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold;
and the production module is used for performing virtual production and manufacturing on the product to be produced according to the adjusted welding process model.
According to a third aspect of the invention, there is provided a non-transitory computer readable storage medium storing a computer program of the method as described above.
The invention provides a virtual production manufacturing method and a virtual production manufacturing system based on welding. On one hand, the virtual manufacturing of the product to be produced is realized, a new product is not required to be trial-manufactured, and the manpower and material resources are reduced; on the other hand, the automation and informatization reduction of the whole process of the virtual manufacturing of the product to be produced are realized, and the production period of the product to be produced is shortened.
Drawings
FIG. 1 is a schematic overall flowchart of a welding-based virtual production method according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating a single machine-to-whole line device mapping process in a welding-based virtual production method according to an embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating a welding numerical simulation process in a virtual production manufacturing method based on welding according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of an overall structure of a virtual welding-based manufacturing system according to an embodiment of the present invention;
fig. 5 is a schematic overall structure diagram of a welding-based virtual production manufacturing apparatus according to an embodiment of the present invention.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
In an embodiment of the present invention, a welding-based virtual production manufacturing method is provided, and fig. 1 is a schematic flowchart of an overall welding-based virtual production manufacturing method provided in an embodiment of the present invention, where the method includes: s101, performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermophysical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint;
the product to be produced is a product to be subjected to virtual production manufacturing, and the embodiment is not limited to the category of the product to be produced. The welded joint is a portion of a product to be produced that needs to be connected by welding. The base material of the welded joint is a material of the welded joint itself, and the welding material is a material selected in advance for welding the welded joint. The base material and the welding material of the welding joint may be the same or different. The thermophysical property parameters characterize various characteristics reflected when the corresponding welding material is used to weld the base metal of each weld joint. Such as modulus of elasticity and poisson's ratio. The elastic-plastic calculation refers to calculating the elasticity and plasticity of the welded joint. The welding parameters refer to physical quantities selected for ensuring the welding quality during welding, such as welding current, arc voltage, heat input and the like. The welding sequence is the sequence of welding all the welding joints in the product to be produced. In the embodiment, the thermophysical performance parameters corresponding to the base metal and the preset welding material of each welding joint in the product to be produced are used as input, and elastic-plastic calculation, deformation analysis and stress analysis are performed on each welding joint to obtain the welding parameters and the welding sequence of each welding joint.
S102, acquiring welding process release and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process release of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint;
and the welding process allowance is obtained according to the deformation after welding and the process pre-deformation design. The welding tool reverse deformation amount means that a deformation is artificially made on a weldment in advance according to the rule that the deformation occurs in production, and the deformation is opposite to the deformation direction occurring after welding and has the same value. And counting the deformation of each welding joint to be used as the welding deformation tolerance allowance of each welding joint. And determining the deformation of each welded joint after welding according to the welding parameters of each welded joint, and outputting a process pre-deformation design, thereby obtaining the welding process allowance of each welded joint. And generating a three-dimensional process model of the product to be produced according to the welding process allowance of each welding joint. The welding tool reversible deformation comprises a boundary constraint point, a reverse deformation amount, a reverse acting force and the like. And designing three-dimensional process equipment according to the guidance of the welding tool reversible deformation amount of each welding joint.
S103, generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment, the welding sequence and the welding parameters of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each procedure in the welding process model until the productivity of the adjusted welding process model is larger than or equal to the preset threshold;
the method comprises the steps of combining and loading a three-dimensional process model and process three-dimensional equipment of a product to be produced into a three-dimensional off-line programming scene, and simulating a welding process of the product to be produced through three-dimensional off-line programming to realize programming of a workpiece and prejudgment of tool design requirements. And simultaneously, rigid fixing design is carried out on positions with overlarge welding deformation, and the welding interference positions are sorted and counted to form tooling design and automatic off-line programming design. In addition, the welding parameters and the welding sequence of each welding joint are optimized, off-line programming is carried out by taking the optimized welding sequence and the welding parameters as basic parameters, and the welding parameters and the welding sequence are loaded to a welding system to weld each welding joint. And running an off-line programming program to obtain the production takt of each procedure in the welding process. As shown in fig. 2, the productivity of the welding process of the product to be produced is calculated, and each process is loaded through a pre-designed three-dimensional factory building, and the equipment in each factory building is gridded equipment. And if the productivity of the welding process is smaller than the preset prefabrication, adjusting each procedure in the welding process model to improve the productivity. And obtaining an equipment layout diagram of the whole production line through capacity vacancy filling and increase and decrease. For example, all devices of the automated welding production line are laid out on a production line grid with a 5-span length of 120m × 120m, so that the migration and wiring of the devices are facilitated, and a production line flow with calculated capacity mapped to the optimal layout is formed.
And S104, performing virtual production manufacturing on the product to be produced according to the adjusted welding process model.
Specifically, according to the adjusted final welding process model, the production and manufacturing layout of the product to be produced is analyzed and calculated, the number of personnel and equipment required by each process is determined through accounting, key paths in the beats are established, optimization analysis is carried out, and the process division is guaranteed within the range of the beats. And then, simulating the production and manufacturing layout of the product to be produced, wherein the production and manufacturing layout comprises the number of personnel and equipment in each process. And loading the rhythm of the three-dimensional off-line programming generation automatic production into software such as APSEN and the like, and verifying the production and manufacturing layout, including the conformity of the three-dimensional process input material and the three-dimensional tool. If the verification result does not meet the requirement, the generated manufacturing layout is adjusted. According to the final production manufacturing layout.
In the embodiment, each welding joint is analyzed according to the base metal of each welding joint in the product to be produced and the thermal physical performance parameters corresponding to the preset welding materials, so that the welding parameters and the welding sequence of each welding joint are obtained, a welding process model of the product to be produced is generated according to the welding parameters and the welding sequence based on three-dimensional off-line programming, and the product to be produced is subjected to virtual production and manufacturing according to the welding process model. On one hand, the virtual manufacturing of the product to be produced is realized, a new product is not required to be trial-manufactured, and the manpower and material resources are reduced; on the other hand, the automation and informatization reduction of the whole process of the virtual manufacturing of the product to be produced are realized, and the production period of the product to be produced is shortened.
On the basis of the embodiment, before the step of performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base material of each welding joint in a product to be produced and the thermal-physical performance parameters corresponding to preset welding materials, the method also comprises the steps of performing thermal-physical performance test on any base material sample and the welding material sample corresponding to the base material sample to obtain a group of thermal-physical performance parameters; constructing a thermophysical property parameter database according to each group of thermophysical property parameters; and inquiring in a thermophysical performance parameter database according to the base metal and the preset welding material of each welding joint in the product to be produced to obtain a group of thermophysical performance parameters corresponding to the base metal and the preset welding material of each welding joint.
Specifically, each base material sample and a welding material sample corresponding to each base material sample are subjected to a thermophysical property test, and a group of thermophysical property parameters are obtained. And constructing a physical property parameter database based on all the acquired thermophysical property parameters, for example, performing thermophysical property tests on common materials such as the parent material sample Q345C and SMA490BW, and materials such as the welding material sample carbon fiber, titanium alloy, super-strong steel and the like.
On the basis of the above embodiments, the thermophysical property parameters in the present embodiment include one or more of elastic modulus, poisson's ratio, shear modulus, tensile strength, and yield strength.
On the basis of the above embodiment, in this embodiment, the step of performing elastic-plastic calculation, deformation analysis, and stress analysis on each welding joint in the product to be produced according to the base metal of each welding joint in the product to be produced and the thermal physical performance parameter corresponding to the preset welding material to obtain the welding parameter and the welding sequence of each welding joint specifically includes: constructing an initial three-dimensional model of a product to be produced based on modeling simulation software and three-dimensional linking software, and determining a welding joint in the initial three-dimensional model; and performing elastic-plastic calculation on each welding joint based on numerical calculation and optimization software, and simultaneously performing deformation analysis and stress analysis on each welding joint to obtain welding parameters and a welding sequence of each welding joint.
Specifically, an initial three-dimensional model design of the product to be generated is constructed using modeling simulation software, such as Ansys, sysswell, and Abqus. The weld joint in the initial three-dimensional model is determined using three-dimensional engagement software, preferably CATIA software. The CATIA software is high-grade CAD/CAM software developed by Dasuo airplane of France, and has strong song design function. CATIA software is used, and the format of the initial three-dimensional model is changed into a common IGS or STP format to be applied to different subsequent software. On the basis of the initial three-dimensional model, according to design structure and manufacturing technical requirements, the process three-dimensional drawing design of the product to be produced is completed, and the first design structure perfection is carried out on the position where the welding seam structure and the chamfer arc exist. And importing the three-dimensional diagram of the process design structure into numerical calculation and optimization software, preferably SYSWELD software, so as to perform elastic-plastic calculation on each welding joint. Meanwhile, the process design structure is imported into numerical calculation and optimization software, preferably ABQUS software is used, so that deformation analysis and stress analysis are carried out on each welding joint, and welding parameters and a welding sequence of each welding joint are obtained. And then, according to the calculated welding deformation of each welding joint, re-optimizing the process three-dimensional structure model, optimizing the position with the welding shrinkage, and acquiring the process yield and welding pre-denaturation data of welding.
As shown in fig. 3, since the cold-hot work shrinkage deformation amount needs to be taken into consideration in the manufacturing process of the welding process, the welding process needs to calculate the reverse deformation amount, the welding shrinkage amount, and the blanking allowance of the design material. And loading theoretical welding seams on the model structure through the thermophysical performance test and the heat source parameter check corresponding to the base metal and the preset welding material of each welding joint in the product to be produced, namely increasing non-process yield in the structural model, and calculating the model structure through ABQUS and SYSWELD software. The calculation flow is as follows: meshing and perfecting an optimized calculation model; loading vehicle type design combination working conditions; outputting initial deformation trend and stress concentration points through elastic-plastic finite source calculation; adding the discharge amount to a designed theoretical three-dimensional model to form a three-dimensional process model; the deformation position of the workpiece is determined through analysis of the overall deformation trend of the welding machine, the boundary constraint point, the reverse deformation and the reverse acting force are marked by three-dimensional software, a mechanical clamping model is generated, and three-dimensional process equipment is guided to be designed.
On the basis of the foregoing embodiments, the step of generating the three-dimensional process model of the product to be produced according to the welding process allowance corresponding to the welding parameter in this embodiment specifically includes: acquiring the post-welding deformation of each welding joint according to the welding parameters of each welding joint; optimizing the welding joints with welding shrinkage in the initial three-dimensional model of the product to be produced according to the deformation after welding to obtain the welding process allowance of each welding joint; and adding the welding process allowance into the initial three-dimensional model of the product to be produced, and generating the three-dimensional process model of the product to be produced.
On the basis of the foregoing embodiments, the step of generating the three-dimensional process equipment of the product to be produced according to the welding tool reverse deformation amount corresponding to the welding parameter in this embodiment specifically includes: acquiring a deformation position of the initial three-dimensional model according to welding parameters of each welding joint; generating a mechanical clamping model according to the tool reversible deformation amount of each deformation position; generating three-dimensional process equipment of a product to be produced according to the mechanical clamping model; the tool reversible deformation amount comprises boundary constraint points, reverse deformation amount and reverse acting force of each deformation position.
On the basis of the above embodiments, the processes in the welding process model in the present embodiment include one or more of assembling, welding, polishing, inspecting, detecting, and adjusting.
Specifically, the off-line program of one or more processes of assembling, welding, polishing, detecting and adjusting is completed through three-dimensional off-line programming, and automatic completion of each process is realized. And after the preset times of adjustment, the productivity of the welding process model is still smaller than a preset threshold value, namely the requirement of productivity design cannot be met, and then the off-line programs of all the procedures are separated.
On the basis of the foregoing embodiments, in this embodiment, the step of adjusting each process in the welding flow model until the productivity of the adjusted welding flow model is greater than or equal to the preset threshold further includes: and calculating one or more of welding quality, welding rhythm and welding material quota of each procedure in the adjusted welding process model.
Specifically, the welding wire consumption, the shielding gas consumption, the electric energy consumption of the robot and the welding machine, the consumption of compressed air and the like of actual operation are determined through the parameters of each process and the running time of an off-line program of each process, so that the material quota and the cost analysis of the product to be produced are realized. The labor hour, material consumption, and the like of each process are obtained by determining the production energy. The consumable order can be automatically issued to the bidding center according to the material consumption, and closed-loop information management of production plan, production consumption statistics, automatic ordering of the consumable order and material detection feedback is formed.
In another embodiment of the present invention, a welding-based virtual production manufacturing system is provided, and fig. 4 is a schematic diagram of an overall structure of the welding-based virtual production manufacturing system provided in the embodiment of the present invention, where the system includes an obtaining module 1, a generating module 2, an adjusting module 3, and a production module 4; wherein:
the acquisition module 1 is used for performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint; the generation module 2 is used for acquiring welding process release and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process release of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint; the adjusting module 3 is used for generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and adjusting each procedure in the welding process model if the productivity of the welding process model is smaller than a preset threshold value until the productivity of the adjusted welding process model is larger than or equal to the preset threshold value; and the production module 4 is used for performing virtual production and manufacturing on the product to be produced according to the adjusted welding process model.
In the embodiment, each welding joint is analyzed according to the base metal of each welding joint in the product to be produced and the thermal physical performance parameters corresponding to the preset welding materials, so that the welding parameters and the welding sequence of each welding joint are obtained, a welding process model of the product to be produced is generated according to the welding parameters and the welding sequence based on three-dimensional off-line programming, and the product to be produced is subjected to virtual production and manufacturing according to the welding process model. On one hand, the virtual manufacturing of the product to be produced is realized, a new product is not required to be trial-manufactured, and the manpower and material resources are reduced; on the other hand, the automation and informatization reduction of the whole process of the virtual manufacturing of the product to be produced are realized, and the production period of the product to be produced is shortened.
On the basis of the above embodiment, the embodiment further includes an inquiry module, configured to perform a thermophysical performance test on any parent material sample and a welding material sample corresponding to the parent material sample, so as to obtain a set of thermophysical performance parameters; constructing a thermophysical property parameter database according to each group of thermophysical property parameters; and inquiring in a thermophysical performance parameter database according to the base metal and the preset welding material of each welding joint in the product to be produced to obtain a group of thermophysical performance parameters corresponding to the base metal and the preset welding material of each welding joint.
On the basis of the above embodiments, the thermophysical property parameters in the present embodiment include one or more of elastic modulus, poisson's ratio, shear modulus, tensile strength, and yield strength.
On the basis of the foregoing embodiment, the obtaining module in this embodiment is specifically configured to: constructing an initial three-dimensional model of a product to be produced based on modeling simulation software and three-dimensional linking software, and determining a welding joint in the initial three-dimensional model; and performing elastic-plastic calculation on each welding joint based on numerical calculation and optimization software, and simultaneously performing deformation analysis and stress analysis on each welding joint to obtain welding parameters and a welding sequence of each welding joint.
On the basis of the foregoing embodiments, the generating module in this embodiment is specifically configured to: acquiring the post-welding deformation of each welding joint according to the welding parameters of each welding joint; optimizing the welding joints with welding shrinkage in the initial three-dimensional model of the product to be produced according to the deformation after welding to obtain the welding process allowance of each welding joint; and adding the welding process allowance into the initial three-dimensional model of the product to be produced to generate the three-dimensional process model of the product to be produced.
On the basis of the foregoing embodiments, the generating module in this embodiment is specifically configured to: acquiring a deformation position of the initial three-dimensional model according to welding parameters of each welding joint; generating a mechanical clamping model according to the tool reversible deformation amount of each deformation position; generating three-dimensional process equipment of a product to be produced according to the mechanical clamping model; the tool reversible deformation amount comprises boundary constraint points, reverse deformation amount and reverse acting force of each deformation position.
On the basis of the above embodiments, the processes in the welding process model in the present embodiment include one or more of assembling, welding, polishing, inspecting, detecting, and adjusting.
On the basis of the above embodiments, the embodiment further includes a calculation module, configured to calculate one or more of welding quality, welding tact, and a welding material quota of each process in the adjusted welding process model.
The present embodiment provides a virtual production manufacturing apparatus based on welding, and fig. 5 is a schematic diagram of an overall structure of the virtual production manufacturing apparatus based on welding according to the embodiment of the present invention, where the apparatus includes: at least one processor 51, at least one memory 52, and a bus 53; wherein,
the processor 51 and the memory 52 are communicated with each other through a bus 53;
the memory 52 stores program instructions executable by the processor 51, and the processor calls the program instructions to execute the methods provided by the above method embodiments, for example, the method includes: performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint; the method comprises the steps of obtaining welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint; generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each process in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold; and performing virtual production manufacturing on the product to be produced according to the adjusted welding process model.
The present embodiments provide a non-transitory computer-readable storage medium storing computer instructions that cause the computer to perform the methods provided by the above method embodiments, for example, including: performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint; the method comprises the steps of obtaining welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint; generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each process in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold; and performing virtual production manufacturing on the product to be produced according to the adjusted welding process model.
Those of ordinary skill in the art will understand that: all or part of the steps for implementing the method embodiments may be implemented by hardware related to program instructions, and the program may be stored in a computer readable storage medium, and when executed, the program performs the steps including the method embodiments; and the aforementioned storage medium includes: various media that can store program codes, such as ROM, RAM, magnetic or optical disks.
The above-described embodiments of the virtual production manufacturing apparatus based on welding are merely illustrative, wherein the units illustrated as separate components may or may not be physically separate, and the components displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment. One of ordinary skill in the art can understand and implement it without inventive effort.
Through the above description of the embodiments, those skilled in the art will clearly understand that each embodiment can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware. With this understanding in mind, the above-described technical solutions may be embodied in the form of a software product, which can be stored in a computer-readable storage medium such as ROM/RAM, magnetic disk, optical disk, etc., and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute the methods described in the embodiments or some parts of the embodiments.
Finally, the method of the present application is only a preferred embodiment and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A virtual production manufacturing method based on welding, comprising:
performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint;
the method comprises the steps of obtaining welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of a product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint;
generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each process in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold;
performing virtual production manufacturing on the product to be produced according to the adjusted welding process model;
the method specifically comprises the following steps of performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint in a product to be produced according to base materials of each welding joint in the product to be produced and thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint:
constructing an initial three-dimensional model of a product to be produced based on modeling simulation software and three-dimensional linking software, and determining a welding joint in the initial three-dimensional model;
performing elastic-plastic calculation on each welding joint based on numerical calculation and optimization software, and simultaneously performing deformation analysis and stress analysis on each welding joint to obtain welding parameters and a welding sequence of each welding joint;
the step of obtaining the welding process discharge amount of each welding joint according to the welding parameters of each welding joint, and generating the three-dimensional process model of the product to be produced according to the welding process discharge amount of each welding joint specifically comprises the following steps:
acquiring the post-welding deformation of each welding joint according to the welding parameters of each welding joint;
optimizing the welding joints with welding shrinkage in the initial three-dimensional model of the product to be produced according to the post-welding deformation to obtain the welding process allowance of each welding joint;
adding the welding process allowance into the initial three-dimensional model of the product to be produced, and generating a three-dimensional process model of the product to be produced;
the method comprises the following steps of obtaining tool reversible deformation amount of each welding joint according to welding parameters of each welding joint, and generating three-dimensional process equipment of a product to be produced according to the tool reversible deformation amount of each welding joint, wherein the steps specifically comprise:
acquiring a deformation position of the initial three-dimensional model according to welding parameters of each welding joint;
generating a mechanical clamping model according to the tool reversible deformation amount of each deformation position;
generating three-dimensional process equipment of the product to be produced according to the mechanical clamping model;
the tool reversible deformation amount comprises boundary constraint points, reverse deformation amount and reverse acting force of each deformation position.
2. The method according to claim 1, characterized in that before the steps of performing elasto-plastic calculation, deformation analysis and stress analysis on each welded joint according to the thermophysical property parameters corresponding to the parent metal and the preset welding material of each welded joint in the product to be produced, further comprising:
for any parent material sample, carrying out thermophysical performance test on the parent material sample and a welding material sample corresponding to the parent material sample to obtain a group of thermophysical performance parameters;
constructing a thermophysical property parameter database according to each group of thermophysical property parameters;
and inquiring in the thermophysical performance parameter database according to the base metal and the preset welding material of each welding joint in the product to be produced to obtain a group of thermophysical performance parameters corresponding to the base metal and the preset welding material of each welding joint.
3. The method of claim 1, wherein the thermophysical property parameters include one or more of elastic modulus, poisson's ratio, shear modulus, tensile strength, and yield strength.
4. The method of any of claims 1-3, wherein the process steps in the welding process model include one or more of assembling, welding, grinding, inspecting, and adjusting.
5. The method of any of claims 1-3, wherein adjusting the processes in the welding process model until the adjusted productivity of the welding process model is greater than or equal to the predetermined threshold further comprises:
and calculating one or more of welding quality, welding rhythm and welding material quota of each procedure in the adjusted welding process model.
6. A welding-based virtual production manufacturing system, comprising:
the system comprises an acquisition module, a processing module and a control module, wherein the acquisition module is used for performing elastic-plastic calculation, deformation analysis and stress analysis on each welding joint according to the base metal of each welding joint in a product to be produced and the thermal physical performance parameters corresponding to preset welding materials, and acquiring the welding parameters and the welding sequence of each welding joint;
the generating module is used for acquiring welding process discharge and welding tool reversible deformation of each welding joint according to welding parameters of each welding joint, generating a three-dimensional process model of the product to be produced according to the welding process discharge of each welding joint, and generating three-dimensional process equipment of the product to be produced according to the welding tool reversible deformation of each welding joint;
the adjusting module is used for generating a welding process model of the product to be produced based on three-dimensional off-line programming according to the three-dimensional process model, the three-dimensional process equipment and the welding sequence of the product to be produced, and if the productivity of the welding process model is smaller than a preset threshold, adjusting each procedure in the welding process model until the adjusted productivity of the welding process model is larger than or equal to the preset threshold;
the production module is used for performing virtual production manufacturing on the product to be produced according to the adjusted welding process model;
wherein the obtaining module is specifically configured to:
constructing an initial three-dimensional model of a product to be produced based on modeling simulation software and three-dimensional linking software, and determining a welding joint in the initial three-dimensional model;
performing elastic-plastic calculation on each welding joint based on numerical calculation and optimization software, and simultaneously performing deformation analysis and stress analysis on each welding joint to obtain welding parameters and a welding sequence of each welding joint;
wherein the generation module is specifically configured to:
acquiring the post-welding deformation of each welding joint according to the welding parameters of each welding joint;
optimizing the welding joints with welding shrinkage in the initial three-dimensional model of the product to be produced according to the post-welding deformation to obtain the welding process allowance of each welding joint;
adding the welding process allowance into the initial three-dimensional model of the product to be produced, and generating a three-dimensional process model of the product to be produced;
the generation module is further to:
acquiring a deformation position of the initial three-dimensional model according to welding parameters of each welding joint;
generating a mechanical clamping model according to the tool reversible deformation amount of each deformation position;
generating three-dimensional process equipment of the product to be produced according to the mechanical clamping model;
the tool reversible deformation amount comprises boundary constraint points, reverse deformation amount and reverse acting force of each deformation position.
7. A non-transitory computer-readable storage medium storing computer instructions that cause a computer to perform the method of any one of claims 1 to 5.
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