CN112916650A - High-precision prediction method and system for stamping rebound of high-strength plate part of new energy automobile - Google Patents
High-precision prediction method and system for stamping rebound of high-strength plate part of new energy automobile Download PDFInfo
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Abstract
The invention belongs to the technical field of mechanical manufacturing, die design and manufacturing, materials science, computers and the like, and discloses a new energy automobile high-strength plate part stamping springback high-accuracy prediction method and system considering an initial residual stress field, which comprises the following steps: the surface residual stress of the high-strength steel plate is subjected to unique deterministic analysis on the internal residual stress; predicting a residual stress field of the sheet metal of the high-strength plate part based on the surface test stress; experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part; analyzing a sheet residual stress field of a high-strength plate part of the new energy automobile; and (4) forecasting stamping springback of the new energy automobile high-strength plate part by considering the initial residual stress field. The invention can provide direct technical support for the development of the lightweight technology of the new energy automobile, better relieves and solves the crisis of energy depletion, and has stronger scientific significance and application prospect.
Description
Technical Field
The invention belongs to the technical field of machinery manufacturing, die design and manufacturing, materials science, computers and the like, and particularly relates to a new energy automobile high-strength plate part stamping springback high-accuracy prediction method and system considering an initial residual stress field.
Background
At present, automobiles are used as vehicles for facilitating the travel of people, great convenience is brought to the life of people, the automobile industry becomes one of the large and large-scale important industries in the world after more than 100 years of development, and China also jumps to the position of the first world automobile production and marketing. However, the current automobiles face three problems of energy, public nuisance and safety after prosperous. Research shows that if light weight design is carried out on an automobile without taking measures, energy is saved, consumption is reduced, world energy is probably exhausted in 2050 years, and convenience in life of human beings is difficult to guarantee; environmental pollution caused by exhaust gas generated by automobile oil burning can cause respiratory tract diseases, emphysema, lung cancer and other diseases, and can also become a fatal killer for human health. Therefore, new energy automobiles and light weight designs thereof become the development direction of automobiles in the future and are widely concerned by the industry and academia.
The high-strength steel has excellent characteristics of inherent high hardness, high strength, high toughness and the like, has the advantage of high cost performance compared with other lightweight materials, is one of the most typical materials selected by the automobile lightweight technical design, can account for 60-80% in an automobile, and can be used in places which are easy to be impacted when automobile accidents occur, such as a roof, a bottom, a front anti-collision beam, a side and a tail of the automobile, so that collision deformation and vehicle rolling are reduced, and the safety of a driver and passengers is protected to the maximum extent. The use of high-strength steel plates in large quantities will become the mainstream of automobile development in the future, and is an important way for realizing light weight, low cost, high safety, energy conservation and environmental protection of automobiles.
However, in the process of stamping and forming the high-strength steel plate part of the new energy automobile, a severe rebound phenomenon exists, namely, the part is deformed under the action of force, so that huge stress exists, and the part and the die profile are deviated due to the redistribution of the elastic deformation energy after the die is unloaded. When the resilience exceeds the allowable tolerance, the assembly difficulty of the whole automobile can be obviously increased, the geometric accuracy of components and the assembly accuracy of the whole automobile can be reduced, the running noise of the automobile can be increased, and serious potential safety hazards can be brought to the automobile. The problem of stamping springback of the high-strength steel plate is always the technical bottleneck of forming a high-strength steel vehicle body component, the development of the lightweight potential of the new energy vehicle is limited to a great extent, automobile designers and scientific researchers are puzzled, and the problem is an important problem which needs to be solved urgently.
Generally, the stamping process of the automobile high-strength plate part is complex, and the springback influence factors are numerous. From a theoretical point of view, however, the spring back is mainly due to deformation caused by stress redistribution. The key scientific problem of the springback problem lies in reproducing an initial residual stress field of a high-strength plate part plate, establishing a stamping springback high-precision prediction model considering the initial residual stress field, revealing the influence mechanism of the initial residual stress on the stamping springback, and providing a stamping springback steady control technology to obtain an optimal process combination.
For a long time, people develop a great deal of research work on the aspects of acquisition of initial residual stress of a plate material, prediction and control of stamping rebound through an experimental method, an analytical method and a finite element simulation method, and obtain fruitful research results, and the research status and development trend of the theoretical technology related to the invention are described as follows:
(1) initial residual stress research of high-strength plate part plate
The production process of the new energy automobile high-strength steel plate is complex, the process is difficult to obtain, and the rolling, cooling quenching and other processes can cause the inside of the new energy automobile high-strength steel plate to generate large residual stress, for example, the residual stress fluctuation range of a hot-rolled high-strength steel ring is as high as-100 MPa to 250 MPa. At present, the surface residual stress of a high-strength plate part plate can be obtained by a nondestructive testing technology, but the residual stress of any point in the high-strength plate part plate is difficult to obtain by the nondestructive testing technology, and the technology of the initial residual stress field of the automobile high-strength steel plate is lacked. How to effectively determine the residual stress field is highly concerned by the engineering and academic circles.
However, previous research by the applicant shows that, according to the self-balancing characteristic of the residual stress field of the mechanical part, a surface plane residual stress field prediction method based on the binary fourier series and a surface test stress residual stress field prediction method are provided for a part with a complex manufacturing process and an unknown technological process. The research result of the applicant on the aspect of predicting the existing residual stress field can provide better theoretical basis and method reference for obtaining the residual stress field of the new energy automobile high-strength plate part plate.
(2) Research on prediction of stamping rebound of automobile high-strength steel part
The research on the prediction of stamping springback of high-strength steel parts of automobiles is always a difficult point and a hot point for simulating the numerical forming of plates. The impact of punch rebound is numerous. The stamping rebound is related to the geometric parameters and performance parameters of the plate designed according to the shape characteristics, precision requirements and the like of the stamping part, and is related to the structural parameters of the die and the stamping technological parameters. The stamping rebound of the simple part can be obtained through an experimental method, the time consumption is usually very long, and the material and die cost is extremely high; the method has the advantages that the springback analysis of bending and stretching of simple parts can be conveniently obtained by an analytical method, the research on initial residual stress is less, only a Pengyan professor team of Yanshan university deduces a plate bending springback angle approximate formula containing the initial residual stress, and the result shows that even the smaller residual stress has more obvious influence on the springback of the plate; the complex part stamping springback can be obtained by finite element simulation prediction technology through finite element software simulation such as Ansys, Abaqus, Dynaform or Autoform. Due to the lack of the accurate acquisition method of the initial residual stress field, the research on the punching rebound simulation of the initial residual stress is less at present, and the maximum punching rebound finite element simulation prediction precision is only about 70%. The rebound prediction precision is not high, and the comprehensive relationship with the influence factors is important. At present, the action mechanism of the initial residual stress field on the stamping rebound of the high-strength plate part is not sufficient, the research of a stamping rebound high-precision prediction method considering the initial residual stress field is urgently needed to be carried out, and the conventional plate bending theory and finite element simulation technology can provide better technical support for the research.
Through the above analysis, the problems and defects of the prior art are as follows:
(1) the production process of the new energy automobile high-strength steel plate material is complex and not easy to know in detail, a large amount of residual stress is usually in the interior, the existing method for reproducing the residual stress field of the high-strength steel plate material is lacked, and the action mechanism of the initial residual stress field on the stamping and rebounding of the high-strength plate part is not sufficient.
(2) The stamping rebound of the simple part can be obtained through an experimental method, the time consumption is usually very long, and the material and die cost is extremely high; the springback analysis of the bending and stretching of the simple part can be conveniently obtained by an analytical method, and the research on the initial residual stress is less.
(3) Due to the lack of the accurate acquisition method of the initial residual stress field, the research on the punching rebound simulation of the initial residual stress is less at present, the maximum punching rebound finite element simulation prediction precision is only about 70%, and the rebound prediction precision is not high.
The difficulty in solving the above problems and defects is: the method is characterized in that a prediction method of an initial residual stress field of a high-strength plate part plate of a new energy automobile is urgently needed to be provided, researches on a stamping springback mechanism and a high-precision prediction method of the high-strength plate part in consideration of the initial residual stress field are developed, a steady control method of stamping springback is further provided, a high-precision springback prediction control system is established, theoretical guidance is provided for automobile stamping technology and mold design, and the technical problems of low stamping springback prediction precision and high control and mold testing difficulty of the high-strength plate part of the new energy automobile are solved.
The significance of solving the problems and the defects is as follows: the technical bottleneck that the stamping rebound of the high-strength plate part is difficult to control is expected to be broken through, and the blank of researching the stamping rebound mechanism by carrying out an initial residual stress field at home and abroad is filled; the method has important theoretical significance and engineering practice value for solving the problem of serious stamping springback of high-strength plate parts of new energy automobiles, and has wide application prospect in the field of high-end equipment such as airplanes and ships; the direct technical support can be provided for the development of the high-strength plate part lightweight technology, the crisis that energy is exhausted is well relieved, the convenience of life and traffic of people is ensured, and the high-strength plate part is in a blue sky in the world to help people to be healthy and safe.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method and a system for predicting stamping rebound of a high-strength plate part of a new energy automobile by considering an initial residual stress field.
The invention is realized in such a way that a new energy automobile high-strength plate part stamping springback high-accuracy prediction method and a system considering an initial residual stress field comprise the following steps:
the method comprises the following steps of firstly, analyzing the unique certainty of the surface residual stress of the high-strength steel plate to the internal residual stress;
predicting the residual stress field of the high-strength plate part plate material based on the surface test stress;
step three, experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part;
and step four, analyzing the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile.
And step five, considering the stamping rebound prediction of the new energy automobile high-strength plate part in the initial residual stress field.
Further, in the first step, the unique certainty analysis of the surface residual stress to the internal residual stress of the high-strength steel plate material comprises:
(1) the unique certainty of the surface residual stress to the internal residual stress is proved by using a back-up method;
(2) according to the elastoplasticity theory and the testability of the surface residual stress, the unique determinacy demonstration of the surface residual stress to the internal residual stress of the high-strength steel plate is carried out.
Further, in the second step, the method for predicting the residual stress field of the high-strength steel plate material based on the surface test stress comprises the following steps:
and (3) deducing to obtain a residual stress field integral balance equation by combining the residual stress self-balancing characteristic and the finite element method idea, and establishing an internal residual stress finite element prediction model based on the surface residual stress.
Further, in the third step, the experimental verification of the prediction method of the residual stress field of the high-strength steel plate material includes:
(1) taking the small scaling model and the real part as research objects together, and testing the mechanical property of the high-strength steel material sample by using a tensile testing machine;
(2) and (3) carrying out surface residual stress test by using a Proto iXRD residual stress tester or an ultrasonic residual stress test technology, and testing the residual stress in the model by using an MTS3000 model residual stress analyzer.
Further, in the fourth step, the analysis of the residual stress field of the high-strength steel plate comprises:
and analyzing and counting the residual stress field of the new energy automobile high-strength steel plate obtained by different models, and further macroscopically recognizing the distribution of the residual stress field, so as to provide basic data for the invention to develop the rebound prediction considering the initial residual stress field.
Further, in the fifth step, the prediction of the stamping rebound of the new energy automobile high-strength plate part considering the initial residual stress field comprises the following steps:
(1) a high-precision prediction method for stamping rebound of a high-strength plate part by considering an initial residual stress field;
(2) development and application of a high-precision prediction system for stamping springback of automobile high-strength plate parts.
Further, in the step (1), the prediction of stamping springback of the automobile high-strength plate part considering the initial residual stress field comprises:
(1) the method comprises the following steps of considering an initial residual stress field, and researching a stamping rebound mechanism of a new energy automobile high-strength plate part: a plate bending resilience angle approximate formula based on initial residual stress is combined with the characteristic of the residual self-balancing characteristic, and a high-strength plate part stamping resilience mechanism considering the initial residual stress field is theoretically explored;
(2) establishing a high-precision prediction model of the stamping rebound of the high-strength plate part by considering an initial residual stress field: on the basis of the initial stress prediction method of the high-strength plate, developing numerical simulation theoretical research of a stamping springback finite element considering an initial residual stress field, and establishing a springback high-precision prediction finite element model;
(3) the new energy automobile high-strength plate part stamping springback prediction method is experimentally verified: the new energy automobile high-strength steel plate is adopted to carry out technological parameter formulation, mold design and manufacture, a stamping springback experiment is carried out by utilizing a springback measuring method based on a standard fixture or a springback measuring method based on a female mold, the springback quantity is tested and compared with a simulation result, and the effectiveness of a high-strength plate stamping springback finite element prediction model considering an initial residual stress field is verified;
(4) research on impact of residual stress on stamping resilience of high-strength plate parts of new energy automobiles: and changing the size of the initial residual stress field by utilizing the established high-precision prediction model for the stamping rebound of the high-strength plate part considering the initial residual stress field to obtain the impact rule of the residual stress on the stamping rebound when different initial residual stress fields are obtained.
It is another object of the present invention to provide a computer-readable storage medium storing a computer program which, when executed by a processor, causes the processor to perform the steps of:
predicting a residual stress field of the sheet metal of the high-strength plate part based on the surface test stress;
experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part;
analyzing a sheet residual stress field of a high-strength plate part of the new energy automobile;
high-accuracy prediction of stamping rebound of high-strength plate parts of new energy automobiles.
Another object of the present invention is to provide a system for predicting rebounding of a new energy automobile high strength plate part considering an initial residual stress field, where the system for predicting rebounding of a new energy automobile high strength plate part includes:
the residual stress field prediction module is used for predicting the residual stress field of the high-strength plate part plate material based on the surface test stress;
the experimental verification module is used for realizing the experimental verification of the prediction method of the residual stress field of the plate material of the high-strength plate part;
and the residual stress field analysis module is used for realizing the analysis of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile.
And the stamping rebound prediction module is used for realizing high-precision prediction of stamping rebound of the high-strength plate part of the new energy automobile.
By combining all the technical schemes, the invention has the advantages and positive effects that: the method for acquiring the initial residual stress field of the high-strength plate of the new energy automobile, provided by the invention, is oriented to the problem of stamping rebound of the high-strength plate part and the core scientific problem behind the technical bottleneck, develops the technical research of predicting stamping rebound of the high-strength plate part of the new energy automobile considering the initial residual stress field, has stronger scientific significance and application prospect, and is mainly embodied in that:
(1) the invention breaks through the technical bottleneck that the stamping rebound of the high-strength plate part is difficult to control, and fills the blank of carrying out the research on the stamping rebound mechanism in the initial residual stress field at home and abroad;
(2) the method has important theoretical significance and engineering practice value for solving the problem of serious stamping resilience of the high-strength plate parts of the new energy automobile, and has wide application prospect in the high-end equipment fields of airplanes, ships and the like;
(3) the invention can provide direct technical support for the development of the lightweight technology of the high-strength plate part, better relieves the crisis of energy depletion, ensures the convenience of life and traffic of people, and helps people to be healthy and safe in the world on a blue sky.
The invention has important engineering application and theoretical development value, and the innovation points are as follows:
(1) the invention provides a new theory and a new method for reproducing an initial residual stress field of a new energy automobile high-strength plate part plate based on surface test stress, which solve the problem that the initial residual stress field of a high-strength plate cannot be obtained;
(2) the invention provides a method for predicting stamping rebound of an automobile high-strength plate part by considering an initial residual stress field, develops a system for predicting stamping rebound with high accuracy, and can provide powerful technical support for predicting and controlling stamping rebound with high accuracy.
The invention provides a method for reproducing an initial residual stress field of a high-strength steel plate material based on surface test stress; disclosing a stamping rebound mechanism of the new energy automobile high-strength plate part for carrying out initial residual stress; establishing a high-precision prediction model of stamping rebound of a high-strength plate part of the new energy automobile; the high-precision prediction system for the stamping rebound of the high-strength plate part of the new energy automobile is developed, the blank of carrying out practical initial residual stress fields at home and abroad to carry out high-precision modeling and prediction of the rebound is filled, the international problem that the high-strength rebound is difficult to predict accurately is broken through, the high-precision prediction and the robust control of the stamping rebound of the part are required to be designed and equipped for light weight design of an airplane and the like, and the high-precision prediction system has important practical significance for promoting the development of high-end equipment industries.
The high-accuracy rebound prediction system developed by the invention not only can better solve the problems of long trial calculation period and low rebound accuracy of the existing stamping process, but also can provide important theoretical and tool support for process evaluation, better promote the rapid development of high-end equipment manufacturing industries such as the automobile industry and the like, and bring huge economic benefits for enterprises. The high-precision prediction technology for the stamping resilience of the high-strength steel can provide direct technical support for the development of the lightweight technology of new energy automobiles, well relieve and solve the crisis of energy depletion, ensure the convenience of life and traffic of people, and help people to be healthy and safe in the world in blue sky.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a flowchart of a method for acquiring an initial residual stress field of a high-strength plate of a new energy automobile according to an embodiment of the present invention.
Fig. 2 is a schematic general technical route of a method for obtaining an initial residual stress field of a high-strength plate of a new energy automobile according to an embodiment of the invention.
Fig. 3 is a schematic diagram of a method for acquiring an initial residual stress field of a high-strength plate of a new energy automobile according to an embodiment of the present invention.
FIG. 4 is a schematic diagram of a technical route for a unique deterministic study of surface residual stress versus internal residual stress provided by an embodiment of the present invention.
FIG. 5 is a schematic diagram of a reproduction technique of the initial residual stress field according to an embodiment of the present invention.
Fig. 6 is a schematic diagram of a technical route for researching a stamping rebound mechanism of a new energy automobile high-strength plate part in consideration of an initial residual stress field, provided by an embodiment of the invention.
Fig. 7 is a schematic diagram of a technical route for accurately predicting the punch-back of a high-strength plate by considering an initial residual stress field according to an embodiment of the present invention.
FIG. 8 is a schematic diagram of a punch rebound testing technique according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Aiming at the problems in the prior art, the invention provides a method and a system for acquiring an initial residual stress field of a high-strength plate of a new energy automobile, and the invention is described in detail below with reference to the accompanying drawings.
As shown in fig. 1, the high-accuracy prediction method for stamping springback of a high-strength plate part of a new energy automobile considering an initial residual stress field according to an embodiment of the present invention includes the following steps:
s101, analyzing the unique certainty of the surface residual stress of the high-strength steel plate to the internal residual stress;
s102, predicting a residual stress field of the plate material of the high-strength plate part based on the surface test stress;
s103, experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part;
s104, analyzing a sheet residual stress field of the high-strength plate part of the new energy automobile;
and S105, considering the stamping rebound prediction of the new energy automobile high-strength plate part of the initial residual stress field.
A person skilled in the art can also use other steps to implement the method for obtaining the initial residual stress field of the high-strength plate of the new energy automobile provided by the present invention, and the method for obtaining the initial residual stress field of the high-strength plate of the new energy automobile provided by the present invention in fig. 1 is only one specific embodiment.
The technical solution of the present invention is further described with reference to the following examples.
1. Content, solved scientific problems and goals
(1) Target
The method discloses an action mechanism of the initial residual stress on the stamping rebound of the high-strength plate part, establishes a stamping rebound high-precision prediction model considering an initial residual stress field, forms a whole set of stamping rebound high-precision prediction theory, method and solving strategy, realizes the stamping rebound high-precision prediction and system development and application of the high-strength plate part of the new energy automobile, and lays a solid foundation for efficiently controlling the rebound to obtain an optimal process combination and solve the problem that the rebound is difficult to control.
(2) Summary of the invention
In order to achieve the aim, the invention develops research around a method and a system for predicting stamping rebound of a new energy automobile high-strength plate part by considering an initial residual stress field, and the method comprises the following steps: on the basis of providing a prediction method of an initial residual stress field of a new energy automobile high-strength plate part plate, a stamping rebound mechanism and high-precision prediction considering the initial residual stress field are developed, and the prediction method of the initial residual stress field and the stamping rebound high-precision prediction method are integrated into an automobile high-strength plate part stamping rebound high-precision prediction system and applied to engineering. The block diagram of the research content is shown in fig. 2, and the following four parts of research content are intensively researched:
1) a prediction method of an initial residual stress field of a sheet metal of a high-strength plate part of a new energy automobile;
2) the method comprises the following steps of (1) considering an initial residual stress field, and performing high-accuracy prediction on stamping springback of the automobile high-strength plate part;
3) development and application of a high-precision prediction system for stamping springback of automobile high-strength plate parts.
The specific research tasks of each part are described as follows:
the content one is as follows: method for predicting sheet residual stress field of high-strength plate part of new energy automobile
Aiming at the difficult problem of lack of a residual stress field acquisition method of a high-strength plate part plate, on the basis of exploring the unique certainty of the surface residual stress of the high-strength steel plate to the internal residual stress, a prediction method of the initial residual stress field of the high-strength steel plate based on the surface test stress is provided, the effectiveness of the method is verified through experiments, the obtained residual stress field is further analyzed, and basic data and theoretical basis are provided for further exploring the research on the stamping rebound of the high-strength plate part considering the initial residual stress field. Specific research tasks include:
1) the surface residual stress of the high-strength steel plate is subjected to unique deterministic analysis on the internal residual stress;
2) a prediction method of the sheet residual stress field of the high-strength plate part based on surface test stress;
3) experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part;
4) and (4) analyzing the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile.
And II, content II: high-accuracy prediction of stamping rebound of automobile high-strength plate part by considering initial residual stress field
Aiming at the problem of low stamping rebound prediction precision, on the basis of the research of the invention content I, the existing bending rebound theory is used for reference, the stamping rebound mechanism of the initial residual stress field is analyzed and considered, the existing stamping rebound finite element numerical simulation technology is combined, a high-precision prediction model of the stamping rebound of the high-strength plate part is established and considered, the initial residual stress field is considered, the influence rule of the initial residual stress on the rebound is analyzed, and theoretical support, method guidance and basic data are provided for further researching the steady control technology of the stamping rebound of the high-strength plate part. The specific tasks comprise:
1) analyzing a stamping rebound mechanism in consideration of an initial residual stress field;
2) experimental verification of a high-precision prediction model for stamping springback of a high-strength plate part;
3) and analyzing the influence of the initial residual stress on the stamping rebound of the high-strength plate part.
And thirdly: development and application of high-precision prediction system for stamping rebound of automobile high-strength plate part
For the high accurate prediction of resilience and the steady control technique of resilience that provides, use in the engineering better, will "prediction of initial residual stress field, the high accurate prediction of punching press resilience" two big technologies integration automobile high strength board stamping workpiece resilience steady control system, the system sets up two corresponding modules to carry out engineering application, break through the difficult problem that the prediction precision of resilience is low and control is difficult. Specific research tasks include:
1) designing and developing a stamping springback accurate prediction and robust control system;
2) the system is applied to high-strength stamping parts of new energy automobiles.
(3) Key scientific problem solved
1) The method is used for proving the unique certainty of the surface residual stress on the internal residual stress, and provides a residual stress field prediction method. The surface residual stress is proved to be the only certainty for the internal residual stress, the premise of providing the residual stress field prediction method based on the surface test stress is provided, the firm foundation for realizing the high-precision prediction and the stable control of the stamping rebound is realized, and the method is a key scientific problem.
2) The stamping springback mechanism of the automobile high-strength plate part considering the initial residual stress field is disclosed, a springback high-precision prediction model is established, the new energy automobile high-strength plate part is complex, the stamping forming springback precision is difficult to control, how to comprehensively perform influence factors, particularly influence of the initial residual stress, the high-precision prediction model considering the initial residual stress field is established, the process formulation time, the die debugging period and the production cost can be reduced, the production efficiency of products is improved, and the lightweight application of the new energy automobile high-strength steel plate is boosted. The method is used for carrying out an initial residual stress field, developing the research on the stamping springback mechanism of the automobile high-strength plate part and establishing a high-precision prediction model, is the basis for carrying out steady control, and is a key scientific problem to be solved.
2. The method, technical route, experimental scheme and feasibility analysis
(1) Method of producing a composite material
The invention relates to the deep crossing of multiple disciplines and specialties of mechanical manufacturing, die design and manufacturing, materials science, computers and the like, covers multiple links of basic theoretical research, experimental analysis and numerical calculation, and is a complex, systematic and innovative research work. In order to successfully complete the research task, the invention adopts a method of combining theoretical analysis, experimental research, mechanical modeling and finite element simulation calculation, establishes a whole set of complete high-precision prediction theory and method of the stamping rebound of the high-strength plate part considering the initial residual stress field through key attack of key technical difficulties, develops the system for engineering application, and establishes the control of the stamping rebound of the high-strength plate part of the new energy automobile on the basis of reliable quantitative calculation.
(2) Technical route
The general technical route of the invention is shown in fig. 3, and the specific research tasks of the three parts of research contents are described as follows:
content I research on prediction of residual stress field of new energy automobile high-strength plate part plate
1) The only certainty analysis of the surface residual stress of the high-strength steel plate material on the internal residual stress is as follows: according to the elastoplasticity theory and the testability of the surface residual stress, the unique deterministic demonstration of the surface residual stress to the internal residual stress of the high-strength steel plate is carried out, and the technical route is shown in FIG. 4. The applicant works in earlier stage, and the method proves the unique certainty of the surface residual stress to the internal residual stress by using a back-up method, and can provide theoretical support for demonstration of the unique certainty of the surface residual stress to the internal residual stress of the high-strength steel plate material.
2) The method for predicting the residual stress field of the high-strength steel plate material based on the surface test stress comprises the following steps: and (3) deducing to obtain a residual stress field integral balance equation by combining the residual stress self-balancing characteristic and the finite element method idea, and establishing an internal residual stress finite element prediction model based on the surface residual stress. The applicant theorizes that the technical route of the initial residual stress field reappearance shown in fig. 5 can provide a theoretical reference for predicting the residual stress field of the residual stress field on the surface of the high-strength steel.
3) The prediction method of the residual stress field of the high-strength steel plate material is experimentally verified to be as follows: the mechanical property test is carried out on the high-strength steel material sample by utilizing a tensile tester, the surface residual stress test is carried out by utilizing a Proto iXRD residual stress tester or an ultrasonic residual stress test technology, and the residual stress inside the model is tested by utilizing an MTS3000 model residual stress analyzer. The economy and convenience of the experiment are reached, and the small model and the real part are scaled together to be used as research objects.
4) Analyzing the residual stress field of the high-strength steel plate: and analyzing and counting the residual stress field of the new energy automobile high-strength steel plate obtained by different models, and further macroscopically recognizing the distribution of the residual stress field, so as to provide basic data for the invention to develop the rebound prediction considering the initial residual stress field.
Content two research on high-strength plate stamping springback high-precision prediction considering initial residual stress field
1) The method comprises the following steps of considering an initial residual stress field, and researching a stamping rebound mechanism of a new energy automobile high-strength plate part: in view of the fact that an approximation formula of a plate bending springback angle containing initial residual stress is deduced by a Pengyan professor team of Yanshan university in China, on the basis of research, a stamping springback mechanism of a high-strength plate part considering an initial residual stress field is theoretically explored by combining the characteristics of the residual self-balancing characteristic, and a technical route is shown in FIG. 6, so that a theoretical basis is provided for high-precision prediction of stamping springback.
2) Establishing a high-precision prediction model of the stamping rebound of the high-strength plate part by considering an initial residual stress field: on the basis of the initial stress prediction method of the high-strength plate, the numerical simulation theoretical research of the punching springback finite element considering the initial residual stress field is developed, and a springback high-precision prediction finite element model is established. Fig. 7 shows a technical route for simulation analysis by means of Dynaform software.
3) The new energy automobile high-strength plate part stamping springback prediction method is experimentally verified: the new energy automobile high-strength steel plate used in the first research content is adopted, process parameter setting, mold design and manufacturing are carried out according to the research flow shown in fig. 8, a stamping springback experiment is carried out by utilizing a springback measuring method based on a standard fixture or a springback measuring method based on a concave mold, the springback amount is tested and compared with a simulation result, and the effectiveness of a high-strength plate stamping springback finite element prediction model considering an initial residual stress field is verified.
4) Research on impact of residual stress on stamping resilience of high-strength plate parts of new energy automobiles: and changing the size of the initial residual stress field by utilizing the established high-precision prediction model for the stamping rebound of the high-strength plate part considering the initial residual stress field to obtain the impact rule of the residual stress on the stamping rebound when different initial residual stress fields are obtained.
Content III 'development and application of high-precision prediction system for rebound of high-strength plate stamping part of automobile'
1) Designing and developing a rebound accurate prediction and control system: and establishing a parameter input interface by using VB (visual basic), calling corresponding software by combining corresponding methods provided by the first and second research contents, completing development of corresponding modules, and forming a high-precision prediction system considering the stamping rebound of the initial residual stress field.
2) The system is applied to high-strength stamping parts of new energy automobiles: parts such as a front door of a new energy automobile fender generally comprise various working procedures such as drawing and trimming, the product corner often needs two times of flanging to ensure the forming quality, and the rebound is large in the forming process and difficult to control in size precision. The system is applied to typical high-strength automobile stamping parts, and experiments are developed in domestic known and famous enterprises such as Shanghai general automobile company Limited and the like with better cooperative relationship.
(3) Experimental protocol
In order to finish the method with high efficiency and lowest cost, a small-size model and actual-size parts of a high-strength steel stamping part of a new energy automobile are selected as experimental objects, plate initial stress test equipment, stamping and springback test experiments and stamping part residual stress test experiments are sequentially carried out, and information such as experimental equipment used in the experiments is detailed in the corresponding parts.
(4) Feasibility analysis
The invention fully combines the existing work basis of an applicant and a subject team to carry out research, the general scheme, the research thought and the technical route of the invention have good feasibility, the subject design is reasonable, the technical platform is mature, and the invention has good feasibility in three aspects of theory, technology and condition, and is specifically embodied in that:
the conventional punching springback research technology has low springback prediction precision because the influence of initial residual stress is not carried out, but the punching springback analysis theory, the design technology and the simulation method are relatively mature, so that a better theory and method basis can be provided for carrying out the springback prediction research of the initial residual stress.
In the above embodiments, the implementation may be wholly or partially realized by software, hardware, firmware, or any combination thereof. When used in whole or in part, can be implemented in a computer program product that includes one or more computer instructions. When loaded or executed on a computer, cause the flow or functions according to embodiments of the invention to occur, in whole or in part. The computer may be a general purpose computer, a special purpose computer, a network of computers, or other programmable device. The computer instructions may be stored in a computer readable storage medium or transmitted from one computer readable storage medium to another, for example, the computer instructions may be transmitted from one website site, computer, server, or data center to another website site, computer, server, or data center via wire (e.g., coaxial cable, fiber optic, Digital Subscriber Line (DSL), or wireless (e.g., infrared, wireless, microwave, etc.)). The computer-readable storage medium can be any available medium that can be accessed by a computer or a data storage device, such as a server, a data center, etc., that includes one or more of the available media. The usable medium may be a magnetic medium (e.g., floppy Disk, hard Disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., Solid State Disk (SSD)), among others.
The above description is only for the purpose of illustrating the present invention and the appended claims are not to be construed as limiting the scope of the invention, which is intended to cover all modifications, equivalents and improvements that are within the spirit and scope of the invention as defined by the appended claims.
Claims (9)
1. The high-precision prediction method for the stamping rebound of the high-strength plate part of the new energy automobile considering the initial residual stress field is characterized by comprising the following steps of:
carrying out unique certainty analysis on the internal residual stress by the surface residual stress of the high-strength steel plate;
predicting the residual stress field of the high-strength plate part plate material based on the surface test stress;
carrying out experimental verification on a prediction method of a sheet residual stress field of a high-strength plate part;
analyzing the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile;
and carrying out stamping springback prediction on the new energy automobile high-strength plate part by considering the initial residual stress field.
2. The method for predicting stamping rebound of a new energy automobile high-strength plate part with high accuracy by considering the initial residual stress field according to claim 1, wherein the analysis of the surface residual stress of the high-strength steel plate material for the unique certainty of the internal residual stress comprises the following steps:
(1) the unique certainty of the surface residual stress to the internal residual stress is proved by using a back-up method;
(2) according to the elastoplasticity theory and the testability of the surface residual stress, the unique determinacy demonstration of the surface residual stress to the internal residual stress of the high-strength steel plate is carried out.
3. The method for predicting the stamping rebound of the new energy automobile high-strength plate part with the initial residual stress field taken into consideration according to claim 1, wherein the method for predicting the residual stress field of the high-strength steel plate material based on the surface test stress comprises the following steps: and (3) deducing to obtain a residual stress field integral balance equation by combining the residual stress self-balancing characteristic and the finite element method idea, and establishing an internal residual stress finite element prediction model based on the surface residual stress.
4. The method for predicting stamping springback of a high-strength plate part of a new energy automobile by considering an initial residual stress field according to claim 1, wherein the experimental verification of the method for predicting the residual stress field of the high-strength steel plate material comprises the following steps:
(1) taking the small scaling model and the real part as research objects together, and testing the mechanical property of the high-strength steel material sample by using a tensile testing machine;
(2) and (3) carrying out surface residual stress test by using a Proto iXRD residual stress tester or an ultrasonic residual stress test technology, and testing the residual stress in the model by using an MTS3000 model residual stress analyzer.
5. The method for predicting stamping rebound of a new energy automobile high-strength plate part with consideration of the initial residual stress field in high accuracy according to claim 1, wherein the analysis of the residual stress field of the high-strength steel plate material comprises the following steps: and analyzing and counting the residual stress field of the new energy automobile high-strength steel plate obtained by different models, and further macroscopically recognizing the distribution of the residual stress field and providing basic data.
6. The method for predicting the stamping rebound of the new energy automobile high strength plate part with consideration of the initial residual stress field according to claim 1, wherein the predicting of the stamping rebound of the new energy automobile high strength plate part with consideration of the initial residual stress field comprises the following steps:
(1) a high-precision prediction method for stamping the high-strength plate part by taking the initial residual stress field into consideration;
(2) development and application of a high-precision prediction system for stamping springback of automobile high-strength plate parts.
7. The method for predicting stamping rebound of a new energy automobile high-strength plate part with consideration of an initial residual stress field according to claim 6, wherein in the step (1), the method for predicting stamping rebound of an automobile high-strength plate part with consideration of an initial residual stress field comprises the following steps:
1) the method comprises the following steps of considering an initial residual stress field, and researching a stamping rebound mechanism of a new energy automobile high-strength plate part: a plate bending resilience angle approximate formula based on initial residual stress is combined with the characteristic of the residual self-balancing characteristic, and a high-strength plate part stamping resilience mechanism considering the initial residual stress field is theoretically explored;
2) establishing a high-precision prediction model of the stamping rebound of the high-strength plate part by considering an initial residual stress field: on the basis of the initial stress prediction method of the high-strength plate, developing numerical simulation theoretical research of a stamping springback finite element considering an initial residual stress field, and establishing a springback high-precision prediction finite element model;
3) the new energy automobile high-strength plate part stamping springback prediction method is experimentally verified: the new energy automobile high-strength steel plate is adopted to carry out technological parameter formulation, mold design and manufacture, a stamping springback experiment is carried out by utilizing a springback measuring method based on a standard fixture or a springback measuring method based on a female mold, the springback quantity is tested and compared with a simulation result, and the effectiveness of a high-strength plate stamping springback finite element prediction model considering an initial residual stress field is verified;
4) research on impact of residual stress on stamping resilience of high-strength plate parts of new energy automobiles: and changing the size of the initial residual stress field by utilizing the established high-precision prediction model for the stamping rebound of the high-strength plate part considering the initial residual stress field to obtain the impact rule of the residual stress on the stamping rebound when different initial residual stress fields are obtained.
8. A computer-readable storage medium storing a computer program which, when executed by a processor, causes the processor to perform the steps of:
predicting a residual stress field of the sheet metal of the high-strength plate part based on the surface test stress;
experimental verification of a prediction method of the residual stress field of the plate material of the high-strength plate part;
analyzing a sheet residual stress field of a high-strength plate part of the new energy automobile;
and (4) forecasting stamping springback of the new energy automobile high-strength plate part by considering the initial residual stress field.
9. The method for predicting the stamping rebound of the new energy automobile high-strength plate part considering the initial residual stress field with high accuracy is implemented according to any one of claims 1 to 8, and the system for predicting the stamping rebound of the new energy automobile high-strength plate part considering the initial residual stress field comprises the following steps:
the residual stress field prediction module is used for predicting the residual stress field of the high-strength plate part plate material based on the surface test stress;
the experimental verification module is used for realizing the experimental verification of the prediction method of the residual stress field of the plate material of the high-strength plate part;
the residual stress field analysis module is used for realizing the analysis of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile; and the stamping rebound prediction module is used for realizing high-precision prediction of stamping rebound of the high-strength plate part of the new energy automobile.
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