CN112966413A - New energy automobile high-strength plate part stamping springback steady control method and system - Google Patents
New energy automobile high-strength plate part stamping springback steady control method and system 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 method and a system for steadily controlling stamping rebound of a high-strength plate part of a new energy automobile, wherein the method for steadily controlling stamping rebound of the high-strength plate part of the new energy automobile comprises the following steps: predicting a sheet residual stress field of a high-strength plate part of the new energy automobile; determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field; considering the steady control of the stamping forming resilience of the automobile high-strength plate part in consideration of the initial residual stress field; experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part. According to the invention, by establishing a steady design theory of the stamping springback of the high-strength plate part in the initial residual stress field, on the basis of research on the significance of the impact of the process parameters on the stamping springback amount of the high-strength steel, the stable design method is applied to optimize the stamping forming process parameters of the high-strength steel, so that the optimal process parameter combination for controlling the springback is obtained, and the stamping springback is effectively controlled.
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 method and a system for stably controlling stamping rebound of a high-strength plate part of a new energy automobile.
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.
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.
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.
The plate material resilience robust design means that a process parameter combination capable of ensuring the minimum part resilience is obtained while controllable factors and noise factors are considered. At present, scholars at home and abroad make great contribution in the aspect of springback robust control by using a robust design method and considering part of stamping processes. The rebound quantity of the obtained process combination is still large because the influence of the residual stress of the plate is not involved. Therefore, 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, a high-strength plate part stamping springback mechanism and a high-precision prediction method study considering the initial residual stress field are developed, a steady control method of stamping springback is further provided, a high-precision springback prediction and steady control system is established, theoretical guidance is provided for automobile stamping technology and mold design, and the technical problems that the high-strength plate part stamping springback prediction precision is low, and control and mold testing difficulty is high are broken through.
Through the above analysis, the problems and defects of the prior art are as follows:
(1) 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.
(2) In the current steady design method proposed by scholars at home and abroad, the rebound quantity of the obtained process combination is still larger because the influence of the residual stress of the plate is not involved.
The difficulty in solving the above problems and defects is: the method comprises the steps of exploring a prediction method of a sheet material residual stress field of a high-strength plate part of a new energy automobile, determining a high-strength plate part stamping springback steady design theory considering an initial residual stress field, researching a steady control method of automobile high-strength plate part stamping forming springback considering the initial residual stress field, developing a high-precision prediction and steady control system considering the initial residual stress field, and carrying out experimental verification on the steady control method of the automobile high-strength plate part stamping forming springback.
The significance of solving the problems and the defects is as follows: the method can provide favorable theoretical guidance for the design and manufacture of the automobile stamping part die, can be applied to high-precision prediction and robust control of stamping rebound of parts of lightweight design equipment such as airplanes and the like, and has important practical significance for improving the development of high-end equipment industry. The developed rebound steady control system not only can better solve the problems of long trial calculation period and low rebound precision of the existing stamping process, but also can provide important theory and tool support for process evaluation, better promote the rapid development of high-end equipment manufacturing industry such as the automobile industry and the like, and bring huge economic benefits for enterprises. The robust control technology of the high-strength steel stamping resilience can provide direct technical support for the development of the lightweight technology of new energy automobiles, better relieves and solves the crisis of energy depletion, ensures the convenience of people living and transportation, and helps people to be healthy and safe in the world in blue sky.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method and a system for stably controlling stamping rebound of a high-strength plate part of a new energy automobile.
The invention is realized in such a way that a new energy automobile high-strength plate part stamping rebound steady control method comprises the following steps:
step one, predicting a residual stress field of a sheet metal of a high-strength plate part of a new energy automobile;
determining a high-strength plate part stamping springback steady design theory by considering an initial residual stress field;
step three, considering the steady control of the stamping forming resilience of the automobile high-strength plate part in the initial residual stress field;
and step four, verifying the experiment of the steady control method for the stamping forming rebound of the automobile high-strength plate part.
Further, in the step one, the prediction of the sheet residual stress field of the new energy automobile high-strength plate part includes:
(1) the surface residual stress of the high-strength steel plate is subjected to unique deterministic analysis on the internal residual stress;
(2) predicting a residual stress field of the sheet metal of the high-strength plate part based on the 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.
Further, in the step one, the prediction of the sheet residual stress field of the new energy automobile high-strength plate part further includes:
(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: the unique certainty of the surface residual stress to the internal residual stress is proved by using a back-up method; according to the elastoplasticity theory and the testability of the surface residual stress, carrying out unique deterministic demonstration of the surface residual stress to the internal residual stress of the high-strength steel plate;
(2) predicting the residual stress field of the high-strength plate part plate material based on the surface test stress: 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;
(3) the experimental verification of the prediction method of the residual stress field of the plate material of the high-strength plate part comprises the following steps: 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; 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;
(4) analyzing the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile: 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.
Further, in the second step, the determination of the stamping springback robust design theory of the high-strength plate part considering the initial residual stress field includes:
the method for the robust design comprises a response surface method, a sensitivity method and other methods, the research is combined with the basic principle of the robust design, the characteristics of each robust design method are analyzed aiming at the characteristics of the forming of the high-strength steel stamping part, and the method is prepared for the stable and robust control of the stamping rebound of the high-strength steel of the automobile.
Further, in step three, the robust control of the stamping forming springback of the automobile high-strength plate part considering the initial residual stress field comprises:
adopting different robust design methods to perform rebound robust control simulation, and comparing analysis results to obtain an optimal rebound robust design method; influence factors and ranges are obtained on the basis of considering the resilience accurate prediction model of the initial residual stress field, and theoretically, the fitting is practical.
Further, in step four, the experimental verification of the robust control method for the stamping forming springback of the automobile high-strength plate part includes:
and (3) carrying out an automobile high-strength steel plate stamping and rebounding experiment by utilizing the stable control method of the new energy automobile high-strength plate part stamping and rebounding considering the initial residual stress field and the obtained optimal process combination, and verifying the effectiveness of the stable control method of rebounding.
Further, the new energy automobile high-strength plate part stamping springback robust control method further comprises development and application of a high-precision prediction and robust control system for automobile high-strength plate stamping springback, and comprises the following steps:
(1) designing and developing a rebound accurate prediction and control system: establishing a parameter input interface by using system development software, calling corresponding software, completing development of corresponding modules, and forming a high-precision prediction and robust control system considering the stamping rebound of an 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 comprise various working procedures of drawing and trimming, the product corner often needs two times of flanging to ensure the forming quality, and the rebound is larger in size and precision and is difficult to control in the forming process; the system is applied to typical automobile high-strength stamping parts, and experiments are carried out in domestic known enterprises with better cooperative relations.
Another object of the present invention is to provide a new energy automobile high-strength plate part stamping springback robust control system applying the new energy automobile high-strength plate part stamping springback robust control method, where the new energy automobile high-strength plate part stamping springback robust control system includes:
the residual stress field prediction module is used for realizing prediction of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile;
the design theory determining module is used for determining the stamping springback steady design theory of the high-strength plate part by considering the initial residual stress;
the steady control module is used for considering the initial residual stress field to realize the steady control of the stamping forming rebound of the automobile high-strength plate part;
and the experiment verification module is used for realizing the experiment verification of the steady control method for the stamping forming rebound of the automobile high-strength plate part.
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 sheet residual stress field of a high-strength plate part of the new energy automobile;
determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field;
the method comprises the steps of considering the steady control of stamping forming springback of the automobile high-strength plate part in an initial residual stress field;
experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
It is a further object of the present invention to provide a computer program product stored on a computer readable medium, comprising a computer readable program for providing a user input interface for performing the following steps when executed on an electronic device:
predicting a sheet residual stress field of a high-strength plate part of the new energy automobile;
determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field;
the method comprises the steps of considering the steady control of stamping forming springback of the automobile high-strength plate part in an initial residual stress field;
experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
By combining all the technical schemes, the invention has the advantages and positive effects that: according to the method for steadily controlling stamping and rebounding of the high-strength plate part of the new energy automobile, provided by the invention, by establishing a steady design theory of stamping and rebounding of the high-strength plate part considering an initial residual stress field and on the basis of research on significance of influence of process parameters on stamping and rebounding amount of high-strength steel, the steady design method is applied, stamping and forming process parameters of the high-strength steel are optimized, an optimal process parameter combination for controlling rebounding is obtained, and stamping and rebounding are effectively controlled.
The method combines theoretical analysis, experimental research, mechanical modeling and finite element simulation calculation, and establishes a whole set of complete high-precision prediction and steady control 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, so as to develop a system for engineering application, and establish the control of the stamping rebound of the high-strength plate part of the new energy automobile on the basis of reliable quantitative calculation. In order to provide a rebound high-precision prediction and rebound steady control technology which is better applied to engineering, the three technologies of initial residual stress field prediction, stamping rebound high-precision prediction and stamping rebound steady control are integrated into a rebound steady control system of a high-strength plate stamping part of an automobile, the system is provided with three corresponding modules and applied to engineering, and the problems of low rebound prediction precision and difficult control are solved.
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 robust control method for stamping springback of a high-strength plate part of a new energy automobile according to an embodiment of the present invention.
Fig. 2 is a general technical route schematic diagram of a new energy automobile high-strength plate part stamping springback robust control method provided by an embodiment of the invention.
Fig. 3 is a schematic diagram of a robust control method for stamping springback of a high-strength plate part of a new energy automobile according to an embodiment of the 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 theoretical research route of a stamping robust design of a high-strength plate part of an automobile according to an embodiment of the present invention.
Fig. 7 is a schematic diagram of a robust design technique for springback considering an initial residual stress field according to an embodiment of the present invention.
Fig. 8 is a schematic diagram of a technical route for designing and developing a robust control system 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 stably controlling stamping rebound of a high-strength plate part 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 robust control method for stamping springback of a high-strength plate part of a new energy automobile provided by the embodiment of the invention comprises the following steps:
s101, predicting a sheet residual stress field of a high-strength plate part of the new energy automobile;
s102, determining a stamping rebound steady design theory of the high-strength plate part by considering an initial residual stress field;
s103, considering the steady control of the stamping forming rebound of the automobile high-strength plate part in the initial residual stress field;
s104, verifying the experiment of the stable control method for the stamping forming rebound of the automobile high-strength plate part.
A person skilled in the art can also use other steps to implement the new energy automobile high-strength plate part stamping springback robust control method provided by the present invention, and the new energy automobile high-strength plate part stamping springback robust control method 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, problem and goal of resolution
(1) Target
The method comprises the steps of revealing the action mechanism of initial residual stress on stamping rebound of a high-strength plate part, establishing a stamping rebound high-precision prediction model considering an initial residual stress field, providing a stamping rebound steady control method considering the initial residual stress field, forming a whole set of theory, method and solving strategy of stamping rebound high-precision prediction and steady control, realizing development and application of a stamping rebound high-precision prediction and steady control system of the high-strength plate part of the new energy automobile, and laying a solid foundation for efficiently controlling rebound to obtain an optimal process combination and solving the problem that the rebound is difficult to control.
(2) Content providing method and apparatus
In order to realize the research target, the invention develops research around a new energy automobile high-strength plate part stamping springback mechanism and a robust control method considering an initial residual stress field: on the basis of providing a prediction method of an initial residual stress field of a new energy automobile high-strength plate part plate, research on a stamping rebound mechanism, high-precision prediction and a robust control technology considering the initial residual stress field is developed, and the prediction method of the initial residual stress field, the high-precision prediction method of the stamping rebound and the robust control technology are integrated into an automobile high-strength plate part stamping rebound high-precision prediction and robust control 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) considering an initial residual stress field, a stamping rebound mechanism and high-precision prediction of the automobile high-strength plate part;
3) the stamping rebound of the high-strength plate part is stably controlled by considering the initial residual stress field;
4) development and application of a high-precision stamping springback prediction and robust control system for automobile high-strength plate parts.
The specific research tasks of each part are described as follows:
the first research content 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. The specific tasks comprise:
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 the second research content is as follows: automobile high-strength plate part stamping springback mechanism considering initial residual stress field and high-accuracy prediction
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. Specific research tasks include:
1) analyzing a stamping rebound mechanism in consideration of an initial residual stress field;
2) establishing a high-precision prediction model of the stamping rebound of the high-strength plate part by considering an initial residual stress field;
3) experimental verification of a high-precision prediction model for stamping springback of a high-strength plate part;
4) and analyzing the influence of the initial residual stress on the stamping rebound of the high-strength plate part.
The research content is three: robust control of stamping rebound for automotive high strength panel parts considering initial residual stress field
Aiming at the difficult problem that the impact factors of the stamping rebound of the automobile high-strength plate part are complex and difficult to control, on the basis of the second invention research content, a stable design theory of the stamping rebound of the high-strength plate part considering the initial residual stress field is established, and on the basis of the research of the influence significance of the process parameters on the stamping rebound quantity of the high-strength steel, the stable design method is applied to optimize the stamping forming process parameters of the high-strength steel, so that the optimal process parameter combination for controlling the rebound is obtained, and the stamping rebound is effectively controlled. Specific research tasks include:
1) considering the stamping resilience steady design theory of the high-strength plate part with the initial residual stress field;
2) considering the initial residual stress field, the method for controlling the stamping forming rebound of the automobile high-strength plate part is stable;
3) experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
The research content is four: development and application of high-precision prediction and robust control system for stamping rebound of automobile high-strength plate part
For aforementioned high accurate prediction of resilience and resilience steady control technique that proposes, use in the engineering better, will "the prediction of initial residual stress field, the high accurate prediction of punching press resilience, punching press resilience steady control" three big technologies integration be automobile high strength board stamping workpiece resilience steady control system, and the system sets up corresponding three module to carry out the engineering application, break through the difficult problem that the prediction precision is low and control is difficult for resilience. 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) Proving the unique certainty of the surface residual stress to the internal residual stress, and providing a residual stress field prediction method
The production process of the new energy automobile high-strength steel plate is complex and not easy to know in detail, a large amount of residual stress is usually in the interior, and the method for reproducing the residual stress field of the high-strength steel plate is lacked at present. 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) Revealing the stamping rebound mechanism of the automobile high-strength plate part considering the initial residual stress field, and establishing a high-precision rebound prediction model
The new energy automobile high-strength plate has complex parts, the stamping forming springback precision is difficult to control, how to comprehensively consider influence factors, especially influence of an initial residual stress field, and establish a high-precision springback prediction model of the high-strength plate stamping part considering the initial residual stress field, so that 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 promoted. The method is based on steady control and is a key scientific problem to be solved by considering 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.
3) Stable control method for stamping rebound of automobile high-strength plate part by considering initial residual stress field
By applying the steady design method, the stamping forming process parameters are optimized to obtain the optimal stamping process combination, the die testing period and the production cost of the stamping process can be obviously reduced, and the rebound prediction precision and the working efficiency are improved. The method has the advantages that the initial residual stress field is considered for carrying out stamping springback steady control, the method has an important guiding effect on the stamping process of the high-strength steel and the design of a die, and has an active promoting effect on the control of the springback of the high-strength steel plate and the application of the high-strength steel plate on a new energy automobile, so that the method is a key problem which needs to be solved in the trend of the invention.
2. The method, technical route, experimental scheme and feasibility analysis
(1) 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 a research task, the invention adopts a method of combining theoretical analysis, experimental research, mechanical modeling and finite element simulation calculation, and establishes a whole set of complete high-precision prediction and steady control theory and method of the high-strength plate part stamping rebound considering the initial residual stress field through key attack of key technical difficulties, so as to develop a system for engineering application and establish 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 four parts of research contents are described as follows:
research content-prediction of residual stress field of new energy automobile high-strength plate part plate material
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. In consideration of the economy and convenience of experiments, the small scaled model and the real part are jointly 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.
Research content II 'high-strength plate stamping springback mechanism considering initial residual stress field and high-precision prediction' research
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 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.
3) The new energy automobile high-strength plate part stamping springback prediction method is experimentally verified: the method comprises the steps of establishing process parameters, designing and manufacturing a die by adopting a new energy automobile high-strength steel plate used in the first research content, carrying out a stamping springback experiment by utilizing a springback measuring method based on a standard fixture or a springback measuring method based on a concave die, testing the springback amount, comparing the springback amount with a simulation result, and verifying the effectiveness of a high-strength plate stamping springback finite element prediction model considering an initial residual stress field.
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.
Research content III' robust control of stamping rebound of high-strength plate part considering initial residual stress field
1) The theory research of the rebound robust design considering the initial residual stress field is as follows: the robust design method comprises a response surface method, a sensitivity method and other methods, the research is combined with the basic principle of the robust design, the characteristics of each robust design method are analyzed aiming at the characteristics of the forming of the high-strength steel stamping part, the method is prepared for the stable and robust control of the stamping rebound of the high-strength steel of the automobile, and the technical route is shown in figure 6.
2) The method for stably controlling the stamping forming resilience of the automobile high-strength steel by considering the initial residual stress field comprises the following steps: and (4) carrying out springback robust control simulation by adopting different robust design methods, and comparing analysis results to obtain the optimal springback robust design method. Fig. 7 shows a rebound robustness design process adopted by using the response surface method, and the influence factors and the range of the technical route are obtained on the basis of considering a rebound accuracy prediction model of the initial residual stress field, and theoretically fit with the reality.
3) The experiment verification of the automobile high-strength steel stamping forming springback steady control method comprises the following steps: and (3) carrying out an automobile high-strength steel plate stamping and rebounding experiment by utilizing the stable control method of the new energy automobile high-strength plate part stamping and rebounding considering the initial residual stress field and the obtained optimal process combination, and verifying the effectiveness of the stable control method of rebounding.
Research content four 'development and application of high-precision prediction and robust control system for rebound of automobile high-strength plate stamping part'
1) Designing and developing a rebound accurate prediction and control system: the technical route of the adopted system design and development is shown in fig. 8, a parameter input interface is established by using VB, corresponding software is called by combining corresponding methods provided by the research contents I, II and III, the development of corresponding modules is completed, and a high-precision prediction and robust control system considering the stamping rebound of the initial residual stress field is formed.
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 overall 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 consideration of three aspects of theory, technology and condition, and is specifically embodied in that:
the existing punching springback research technology does not consider the influence of the initial residual stress field, so that the springback prediction precision is low, but the punching springback analysis theory, the design technology and the simulation method are relatively mature, and a better theory and method foundation can be provided for developing the control research considering the initial residual stress field;
the method can provide favorable theoretical guidance for the design and manufacture of the automobile stamping part die, can be applied to high-precision prediction and robust control of stamping rebound of parts of lightweight design equipment such as airplanes and the like, and has important practical significance for improving the development of high-end equipment industry. The developed high-accuracy rebound prediction and robust control system 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 robust control technology of the high-strength steel stamping resilience can provide direct technical support for the development of the lightweight technology of new energy automobiles, better relieves and solves the crisis of energy depletion, ensures the convenience of people living and transportation, and helps people to be healthy and safe in the world in blue sky.
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 (10)
1. The robust control method for stamping rebound of the high-strength plate part of the new energy automobile is characterized by comprising the following steps of:
predicting a sheet residual stress field of a high-strength plate part of the new energy automobile;
determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field;
the method comprises the steps of considering the steady control of stamping forming springback of the automobile high-strength plate part in an initial residual stress field;
experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
2. The method for robustly controlling stamping springback of a high-strength plate part of a new energy automobile according to claim 1, wherein the prediction of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile comprises:
(1) the surface residual stress of the high-strength steel plate is subjected to unique deterministic analysis on the internal residual stress;
(2) predicting a residual stress field of the sheet metal of the high-strength plate part based on the 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.
3. The method for robustly controlling stamping springback of a high-strength plate part of a new energy automobile according to claim 2, wherein the predicting of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile further comprises:
(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: the unique certainty of the surface residual stress to the internal residual stress is proved by using a back-up method; according to the elastoplasticity theory and the testability of the surface residual stress, carrying out unique deterministic demonstration of the surface residual stress to the internal residual stress of the high-strength steel plate;
(2) predicting the residual stress field of the high-strength plate part plate material based on the surface test stress: 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;
(3) the experimental verification of the prediction method of the residual stress field of the plate material of the high-strength plate part comprises the following steps: 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; carrying out surface residual stress test by using a ProtoiXRD 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;
(4) analyzing the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile: 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.
4. The method for robustly controlling stamping rebound of a high-strength plate part of a new energy automobile according to claim 1, wherein the determination of the high-strength plate part stamping rebound robustly designing theory considering initial residual stress field comprises: the robust design method comprises a response surface method, a sensitivity method and other methods, combines the basic principle of robust design, analyzes the characteristics of each robust design method aiming at the characteristics of the forming of the high-strength steel stamping part, and prepares for the stable and healthy control of the stamping rebound of the high-strength steel of the automobile.
5. The robust control method for stamping springback of a new energy automobile high-strength plate part as claimed in claim 1, wherein the robust control for stamping forming springback of the automobile high-strength plate part considering an initial residual stress field comprises: adopting different robust design methods to perform rebound robust control simulation, and comparing analysis results to obtain an optimal rebound robust design method; influence factors and ranges are obtained on the basis of considering the resilience accurate prediction model of the initial residual stress field, and theoretically, the fitting is practical.
6. The robust control method for stamping springback of the new energy automobile high-strength plate part as claimed in claim 1, wherein experimental verification of the robust control method for stamping forming springback of the automobile high-strength plate part includes: and (3) carrying out an automobile high-strength steel plate stamping and rebounding experiment by utilizing the stable control method of the new energy automobile high-strength plate part stamping and rebounding considering the initial residual stress field and the obtained optimal process combination, and verifying the effectiveness of the stable control method of rebounding.
7. The new energy automobile high-strength plate part stamping springback robust control method according to claim 1, further comprising development and application of a high-precision prediction and robust control system for automobile high-strength plate stamping springback, comprising:
(1) designing and developing a rebound accurate prediction and control system: establishing a parameter input interface by using system development software, calling corresponding software, completing development of corresponding modules, and forming a high-precision prediction and robust control system considering the stamping rebound of an 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 comprise various working procedures of drawing and trimming, the product corner often needs two times of flanging to ensure the forming quality, and the rebound is larger in size and precision and is difficult to control in the forming process; the system is applied to typical automobile high-strength stamping parts, and experiments are carried out in domestic known enterprises with better cooperative relations.
8. The system for robustly controlling stamping rebounding of the new energy automobile high-strength plate part by applying the method for robustly controlling stamping rebounding of the new energy automobile high-strength plate part as claimed in any one of claims 1 to 7 is characterized by comprising the following steps:
the residual stress field prediction module is used for realizing prediction of the residual stress field of the sheet metal of the high-strength plate part of the new energy automobile;
the design theory determining module is used for determining the stamping springback steady design theory of the high-strength plate part by considering the initial residual stress;
the steady control module is used for considering the initial residual stress field to realize the steady control of the stamping forming rebound of the automobile high-strength plate part;
and the experiment verification module is used for realizing the experiment verification of the steady control method for the stamping forming rebound of the automobile high-strength plate part.
9. 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 sheet residual stress field of a high-strength plate part of the new energy automobile;
determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field;
the method comprises the steps of considering the steady control of stamping forming springback of the automobile high-strength plate part in an initial residual stress field;
experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
10. A computer program product stored on a computer readable medium, comprising computer readable program for providing a user input interface to perform the following steps when executed on an electronic device:
predicting a sheet residual stress field of a high-strength plate part of the new energy automobile;
determining a stamping springback steady design theory of the high-strength plate part by considering an initial residual stress field;
the method comprises the steps of considering the steady control of stamping forming springback of the automobile high-strength plate part in an initial residual stress field;
experimental verification of the steady control method for stamping and forming rebound of the automobile high-strength plate part.
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| CN107729661A (en) * | 2017-10-23 | 2018-02-23 | 成都普什汽车模具有限公司 | Automobile panel curved surface stretch flanging method for controlling springback |
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