1922_基于ProToolkit的止动片冲裁模三维参数化设计
1922_基于ProToolkit的止动片冲裁模三维参数化设计,基于,protoolkit,止动片冲裁模,三维,参数,设计
黄河科技学院本 科 毕 业 设 计 任 务 书工 学院 机械 系 机械设计制造与自动化 专业 08 级 1 班学号 080105039 学生 盛菲菲 指 导 教 师 孙 光 华 毕业设计(论文)题目 基于 Pro/Toolkit 的止动片冲裁模三维参数化设计 毕业设计(论文)工作内容与基本要求(目标、任务、途径、方法,应掌握的原始资料(数据) 、参考资料(文献)以及设计技术要求、注意事项等) (纸张不够可加页)一、工作内容: 查阅相关资料,熟悉毕业设计的内容; 完成与课题相关的文献综述、文献翻译(英译汉)和开题报告; 冲裁件结构分析、工艺分析及相关计算 冲裁模结构设计、冲裁力及模具工作零件的设计计算; 建立相关的模具标准元件数据库; 建立模具各元件的三维参数化模型与模具装配模型; 使用 pro/Toolkit 的 API 函数编程实现模具参数化设计; 模具零件图与装配图绘制; 按照规定的格式要求,撰写毕业设计说明书一份和软件使用说明书一份。 二、基本要求 查阅文献资料不少于 12 篇,其中外文资料不少于 2 篇;文献综述不少于 3000 字,外文文献翻译不少于 3000 字; 所设计的模具结构正确合理; 模具相关元件实现参数化设计; 所生成的模具零件图与装配图符合国家标准; 所有毕业设计文档均需刻入光盘上交; 毕业设计说明书格式规范。 三、主要参考文献: 1 王隆太 机械 CAD/CAM 技术北京:机械工业出版社,20052 仲梁维计算机辅助设计与制造 北京:北京大学出版社,20063 孙光华工装设计.北京:机械工业出版社,20044 单泉等Pro/E 参数化设计从入门到精通北京:机械工业出版社, 20085 张继春 Pro/E 二次开发实用教程北京:北京大学出版社, 20036 (美)Ivor Horton.Visual C+ 2005 入门经典北京:清华大学出版社,2007四、时间安排:1-4 周 明确设计任务,搜集并熟悉设计相关资料,完成开题报告、文献翻译、文献综述及总体方案设计,熟悉相关软件的使用5-6 周 确定模具的结构形式,设计模具各元件,建立相关的模具标准元件数据库;7-8 周 建立模具各元件的三维参数化模型与模具装配模型。9-11 周 编程实现模具参数化设计;完成模具零件图与装配图绘制12 周 撰写与整理毕业设计说明书与软件使用说明书13 周 修改毕业设计说明书、资格审查等14 周 准备答辩毕业设计(论文)时间: 2012 年 2 月 13 日至 2012 年 5 月 20 日计 划 答 辩 时 间: 2012 年 5 月 20 日专业(教研室)审批意见:审批人签名:黄河科技学院毕业设计(论文)开题报告表课题名称 基于 Pro/Toolkit 的止动片冲裁模三维参数化设计课题来源 教师拟订 课题类型 CX 指导教师 孙光华学生姓名 盛菲菲 专 业 机械设计制造及其自动化 学 号 080105039一、调研资料的准备根据任务书的要求,在做本课题前,查阅了与课题相关的资料有:机械 CAD/CAM 技术、计算机辅助设计与制造、工装设计、Pro/E 参数化设计从入门到精通、Pro/E 二次开发实用教程、Visual C+ 2005 入门经典与毕业设计指导等。二、设计的目的与要求 毕业设计是大学教学中最后一个实践性教学环节,通过该设计过程,可以检验学生所学的知识,同时培养学生处理工程中实际问题的能力,因此意义特别重大。所设计的模具结构正确合理;模具相关元件实现参数化设计;所生成的模具零件图与装配图符合国家标准。三、设计的思路与预期成果 1、设计思路首先学习相关软件的安装及应用,完成老师布置的练习。然后确定止动片冲裁模的结构形式、定位标准、参数等,并作必要的计算与校核,建立相关的模具标准元件数据库,建立止动片模具的三维参数化模型及装配模型。使用 pro/Toolkit 的 API 函数编程实现模具参数化设计,模具零件图与装配图绘制。2、预期的成果(1)完成文献综述一篇,不少与 3000 字,与专业相关的英文翻译一篇,不少于 3000 字(2)完成内容与字数都不少于规定量的毕业设计说明书一份(3)绘制装配图,部分零件图(4)刻录包含本次设计的所有内容的光盘一张四、任务完成的阶段内容及时间安排1-4 周 明确设计任务,搜集并熟悉设计相关资料,完成开题报告、文献翻译、文献综述及总体方案设计,熟悉相关软件的使用5-6 周 确定模具的结构形式,设计模具各元件,建立相关的模具标准元件数据库7-8 周 建立模具各元件的三维参数化模型与模具装配模型9-11 周 编程实现模具参数化设计;完成模具零件图与装配图绘制12 周 撰写与整理毕业设计说明书与软件使用说明书13 周 修改毕业设计说明书、资格审查等14 周 准备答辩五、完成设计(论文)所具备的条件因素本人已修完机械 CAD/CAM 技术、计算机辅助设计与制造、工装设计、Pro/E 参数化设计从入门到精通、Pro/E 二次开发实用教程、Visual C+ 2005 入门经典与毕业设计指导等课程,借助图书馆的相关文献资料,以及相关的网络等资源。指导教师签名: 日期: 课题来源:(1)教师拟订;(2)学生建议;(3)企业和社会征集;(4)科研单位提供课题类型:(1)A工程设计(艺术设计) ;B技术开发;C软件工程;D理论研究;E调研报告(2)X真实课题;Y模拟课题;Z虚拟课题 要求(1) 、 (2)均要填,如 AY、BX 等。 黄河科技学院毕业设计 第 1 页基于Pro/toolkit的止动片冲裁模三维参数化设计摘要:本文介绍了在VC的集成开发环境下开发基于 Protoolkit的止动片冲裁模三维参数化设计。提出了利用ProE的开发工具Protoolkit参数化建模和装配的方法。并以止动片冲裁模为例详细介绍了该CAD系统的应用。关键词:Protoolkit;止动片冲裁模;参数化设计Abstract: this paper introduces the integrated development environment in VC next based on the development of the Pro/toolkit stop moving piece of punch die 3 dimensional parametric design. Put forward by using Pro/E development tool to Pro/toolkit parameterized modeling and assembly method. And to stop moving piece of punch die for example detailed introduces the application of CAD system. Keywords: Pro/toolkit; Stop moving piece of punch die; Parametric design 前言参数化设计方法具有高效性、实用性的特点,在产品的系列设计、相似设计及专用 CAD 系统开发方面都具有较大的使用价值。与传统设计方法相比,能够减少重复劳动,提高设计效率,符合现代产品设计要求。人类文明的发展、科技的进步已和数控机床的研究及Protoolkit的三维参数化设计产生了密不可分的关系。实现产品设计的数字化离不开CAD/CAM系统的支持。ProE作为通用的三维CAD/CAM系统在功能上基本能满足产品三维设计要求, 但要高效地进行产品设计以满足更高层次的要求,必须借助于高级开发工具包Protoolkit 1。Protoolkit是PTC 公司为 ProE软件提供的开发工具包,即应用程序接口(API) 。其主要目的是让用户或第方通过C程序代码扩充Pro E系统的功能,开发基于ProE系统的应用程序模块,从而满足用户的特殊要求。Protoolkit工具包提供了开发ProE所需的函数库文件和头文件, 使用户能够定制标准ProE用户界面的能力,自动执行重复性的程序 2,3。通过Pro E集成的内部程序(DII)或外部应用程序(Exe)可以为造型用户提供 黄河科技学院毕业设计 第 2 页自定义的应用程序、设计规划和绘图自动化,,并可以实现应用程序模块与ProE系统的无缝集成 4。1.止动片冲裁模参数化CAD系统功能简介利用Protoolkit提供的开发接口,主要进行数据库接口模型、定制的用户界面模块和零件参数化模块的二次开发 5。本系统由大模块构成通过VC+开发的用户界面模块、利用ProE建立零件模型库及装配关系模型库模块、实现参数化的Pro toolkit应用程序模块和数据库模块。其中各大模块下又划分若干个子模块。各模块相互关联,相互调用。这样便可在ProE的环境下显示止动片冲裁模的三维实体模型。如用户对当前的设计不满意, 可返回用户界面,重新设计,也可在零件模型参数显示界面更改参数变量重新生成零件。2.ProE与 VC接口的实现系统应用 VC 设计应用程序的人机交互界面,利用 ProE 的二次开发包Protoolkit 提供的函数,编写 C 语言代码 6。开发基于ProE的止动片冲裁模三维参数化CAD系统。系统实现的关键是实现Pro E与VC系统的无缝连接:(1)在VisualC+集成环境里建立一个基于常规MFC的动态链接库的工程。(2)在工程的CPP文件中编写 Protoolkit入口函数user-initialize() 和终止函数user-terminate()。(3)系统环境定制a.在工程里设置库文件的环境方法是:ProjecSettingsLink,在Object/Library Modules里添加mpr.lib,protk-dll.lib,prodev-dll.lib,wsock32.lib等库文件名。b.设置头文件、库文件的路径方法是:ToolsOptionsDirectories,给出必要的文件路径。如:D:PROEWILDFIREPROTOOLKITINCLUDESD:PROEWILDFIREPROTOOLKITI486-NTOBJ。(4)注册动态连接文件并运行 黄河科技学院毕业设计 第 3 页在ProE中要运行外部程序,必须对其进行注册。自动注册就是把注册文件放Pro E的启动目录下即可。而手动注册就是在ProE环境下选取ToolsAuxiliary Application对话框加载该注册文件。这样实现的连接后,止动片冲裁模CAD系统就可在ProE环境下调用VC的资源,从而可大大扩充原系统的功能,增强了可视化和交互性,提高产品设计质量和效率。3.止动片冲裁模CAD系统参数化建模的实现利用ProE的开发包Protoolkit提供的函数,在应用程序中通过特征元素树(featureelementtree)自动创建三维模型的方法比较困难,并且开发包Protoolkit没有提供创建全部特征的相关函数。因此,系统采用以人机交互建立的模型为基础,通过动态显示和修改模型的参数变量,来控制模型的结构,达到参数化自动重建的目的 7。一般应用在优化技术上,通过将模型参数化,优化过程中不断对其进行迭代而求出最佳解。参数化建模是参数(变量)而不是数字建立和分析的模型,通过简单的改变模型中的参数值就能建立和分析新的模型。 参数化建模的参数不仅可以是几何参数,也可以是温度、材料等属性参数。在参数化的几何造型系统中,设计参数的作用范围是几何模型。但几何模型不能直接用于进行分析计算,需要将其转化为有限元模型,才能为分析优化程序所用。因此,如果希望以几何模型中的设计参数作为形状优化的设计变量,就必须将设计参数的作用范围延拓至有限元模型,使有限元模型能够根据设计变量的变化,实现有限元模型的参数化。参数化建模技术在辅助建筑设计上的应用越来越广泛,其发展时间短暂,发展速度却令人叹为观止,目前在建或已建成的各种形态各异的建筑或多或少都有参数化软件的设计辅助。3.1在ProE 环境下建立止动片冲裁模系统零件库即在ProE环境下建立用于产生一系列衍生件的三维模型样板。在建立零件模型样板时,要利用参数(Parameters)模块创建参数变量,关系式(Relation)模块建立参数驱动关系, 以保证生成的新模型具有正确的约束和驱动关系 8。同时,参数化模型库的建立也便于零件的统一管理和资源共享。 黄河科技学院毕业设计 第 4 页3.2参数变量的检索参数对象(ParameterObject)和参数值(the Valueofaparameter)都是类型为结构体的一种数据对象,参数的检索、更新都要涉及到这两个数据结构 9。Protoolkit函数实现模型参数的检索,首先必须得到指向该参数对象的指针,若用户已知参数的名称,调用ProParameterInit()直接获取该参数名对应的参数对象指针。若用户不知道参数的名称,可调用ProPara-meterVisit()函数遍历模型中的全部参数 10。把检索模型的参数指针存于类型为参数(ProParameter)的指针数组中。3.3三维模型的参数化重建要实现参数化, 必须实现数据流双向传动,即一方面从基准模型设计参数传递到交互界面,供用户修改另一方面,用户修改后的新参数值要从用户界面返回到基准模型以实现参数更新,进而重建零件模型 11。首先用ProMdlRetrieve()把零件从模型库调入内存,通过ProParameterlint()或ProParameterVisit()函数检索出参数对象之后,通过(ProParameter)指针数组中各参数的指针调用ProParameterValueGet()函数可获得类型为参数值(ProParameterValue)的结构体变量,以此结构体变量为输入参数调用函数ProParameterValueGet()可设置修改参数之值 12。在参数更新之前,须按照约束条件进行参数值合法性检查。满足约束条件的新的参数值才能向模型参数值结构体赋值。最后,用ProSolidRegenerate()函数再生三维模型,完成零件的参数化自动重建。这样,通过函数检索参数变量并对其赋值,再通过关系式传递驱动关系和约束关系,便可控制模型的几何特征,重建模型。应用该系统设计止动片冲裁模的整体三维装配图。4.结论本文利用VC开发环境和ProE二次开发技术, 基于特征建模和参数化设计,分析了止动片冲裁模装配组成及主要零部件之间的联结关系, 建立了主要零部件和装配实体模型。确定了止动片冲裁模的主要零件的参数化寸, 建立各尺寸之间的约束关系, 进行止动片冲裁模三维参数化设计和装配, 实现了设计过程中的自动化和可视化, 大大缩短设计周期、提高设计质量和效率。同时, 系统对其 黄河科技学院毕业设计 第 5 页它参数化CAD系统的开发有借鉴作用。参考文献:1.刘文生,等。基于 ProE实体模型的参数化二次开发J.制造业自动化,2005(8):12-14.2.金淘,陈敏,童水光。ProENGINEER软件的二次开发技术J. 计算机工程及应用,2001(13):148-152.3.李世国。 Protoolkit程序设计M.北京:机械工业出版社 ,2003.4.ZANGZ,SARHADIM.An intergration CAD/CAM systerm for automated composite manufacture JJournal of Materials Processing Technology,1996,61(1-2).5.张继春 Pro/E 二次开发实用教程 北京:北京大学出版社,20036.仲梁维 计算机辅助设计与制造 北京:北京大学出版社,20067刘洁三维 CAD 标准件库的建模与实现方法研究D西安:西安理工大学,20018.(美)Ivor Horton.Visual C+ 2005 入门经典北京:清华大学出版社,20079.黄圣杰,张益三,洪立群ProEngineer 2001 高级开发实例M北京:电子工业出版社,200110.张超,张益华 ProE 二次开发技术在齿轮三维参数化设计中的应用J,2004.11.单泉等 Pro/E 参数化设计从入门到精通 北京:机械工业出版社,200812FFCPro Toolkit users GuideUSA:PTC,2003 毕业设计文献综述院 ( 系 ) 名 称 工 学 院 机 械 系专 业 名 称 机 械 设 计 制 造 及 其 自 动 化学 生 姓 名 盛 菲 菲指 导 教 师 孙 光 华2012 年 03 月 10 日 Recent achievements in computer aided process planning and numerical modelling of sheet metal forming processesM. Tisza*Manufacturing and processingAbstractPurpose: of this paper: During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as one of the most important engineering tools in sheet metal forming, particularly in the automotive industry. This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. The purpose of this paper is to give a general overview about the recent achievements in this very important field of sheet metal forming and to introduce some special results in this development activity.Design/methodology/approach: Concerning the CAE activities in sheet metal forming, there are two main approaches: one of them may be regarded as knowledge based process planning, whilst the other as simulation based process planning. The author attempts to integrate these two separate developments in knowledge and simulation based approach by linking commercial CAD and FEM systems.Findings: Applying the above approach a more powerful and efficient process planning and die design solution can be achieved radically reducing the time and cost of product development cycle and improving product quality.Research limitations/implications: Due to the different modelling approaches in CAD and FEM systems, the biggest challenge is to enhance the robustness of data exchange capabilities between various systems to provide an even more streamlined information flow.Practical implications: The proposed integrated solutions have great practical importance to improve the global competitiveness of sheet metal forming in the very important segment of industry.Originality/value: The concept described in this paper may have specific value both for process planning and die design engineers.Keywords: Analysis and modelling; Knowledge and simulation based systems1. Introduction In the recent years, the role and importance of metal forming processes in manufacturing industry have been continuously increasing primarily due to its material- and cost-effective nature. It is further emphasised by the recent advances in tools, materials and design, which in turn provide significant improvements in the mechanical properties and tolerances of the products. It is also characteristic for metal forming processes that the final shape of the component cannot be produced generally by a single operation, but more often several operations should be performed to transform the initial simple geometry into a more complex product. Moreover, in the recent years metal forming develops in the direction of net-shape or near-net-shape manufacturing to reduce the need for subsequent machining operations and to minimise the total manufacturing represent very important and complex tasks. The global competition also requires that manufacturing industry besides the skill and the experience accumulated in the shop practice should increasingly utilise proven techniques of Computer Aided Engineering for rapid and cost effective process design and tool manufacturing. The application of various methods of Computer Aided Engineering has become one of the most important topics in manufacturing industries and particularly in the automotive industry. The application of various CAE techniques practically covers the full product development cycle from the conceptual product design through the process planning and die design up to the manufacturing phase of the production. CAE techniques are widely used in sheet metal forming, for example to predict the formability, to determine the type and sequences of manufacturing processes and their parameters, to design forming tools, etc. The importance of the application of CAE tools becoming more and more important as the manufactured parts are becoming ever increasingly complex. As the need for the widespread application of CAE techniques driven by the demand of global competitiveness accelerates, the need for a robust and streamlined Process and Die Design Engineering (PDDE) becomes more and more crucial. Recently, there are two main approaches to achieve these goals. One of them is the application of knowledge-based expert systems, which are generally based on simplified plasticity theory and empirical technological rules. There are a great number of papers dealing with the exclusive use of knowledge-based systems both in sheet and bulk metal forming 1-3. However, the exclusively knowledge based solutions have certain disadvantages: they usually cannot provide an enough accurate solution to the problem since these systems are generally based on simple technological rules with limited validity. Therefore knowledge-based systems cannot predict for example the material flow, and usually cannot provide the accurate stress and strain distribution inside the component. As another approach, numerical techniques (recently mainly finite element modelling) are applied for the analysis of the plastic deformation 4-6. The main objectives of the application of numerical process simulation in metal forming are to determine appropriate process parameters and to develop adequate die design by process simulation, to improve part quality by predicting process limits and preventing flow induced defects. Besides these, numerical process simulation also leads to reducing process and die try-out, as well as shorter lead times, while significantly reducing manufacturing costs. But the exclusive use of numerical modelling like it is the case in the exclusive use of knowledge-based systems has also some drawbacks, too. In spite of the enormous development of hardware and software facilities, the reliability of results is often dependent on the experiences of the user. It is partly due to the large number of operating parameters whose influence should be investigated, and partly due to the numerical difficulties caused by the complexity of the applied mathematical model to describe the material behaviour. Therefore, in the recent years the integration of these two fields (i.e. the knowledge-based systems and numerical modelling) has gained primary importance 7. 2. Process planning and die-design in sheet metal One of the main drawbacks in industrial practice hindering the even more wide application of simulation techniques that the output results of simulation packages are not usually directly and easily usable for computer aided die design. Obviously, there are tremendous efforts to successfully link CAD and FEM systems, however, still there are a lot to do in this field 8. This solution requires a fully integrated approach of computer aided product design, process planning and die design, as well as the finite element simulation of the forming processes. It means that simulation tools should be efficiently used throughout the whole product development cycle 9. This concept will be illustrated through the examples of automotive part production. In our practice, we use Unigraphics NX 4 as a commercial CAD system for supporting the Computer Aided Process Planning and Die Design tasks and the AutoForm 4.05 and PAM-STAMP 2G are used as the numerical simulation tools, however, the principles applied here can be similarly adopted by using different CAD and simulation packages, too. Before analysing this integrated solution, lets summarize the main features of forming process planning and die design in so-called conventional CAD environment .2.1Process planning and die-design in conventional CAD environmentStamping industry applies CAD techniques both in the process planning and die design already for many years. However, in a traditional” CAD environment, these are practically stand-alone solutions, i.e. for example a knowledge based process planning solution is applied for the determination of the necessary types of forming processes, even in some cases, the forming sequences can be determined in this way together with the appropriate process paramteres, too. After determining the process sequences and process parameters, the forming dies are designed using sophisticated CAD systems, however, still we do not have any evidence whether the designed tools will provide the components with the prescribed properties. Therefore, before it goes to the production line, usually a time- and cost consuming try-out phase follows, as it is shown in Fig.1 If the try-out is successful, i.e. the die produces parts with no stamping defects, it will be sent to the stamping plant for production. On the other hand, if splitting or wrinkling occur during the tryout, the die set needs to be reworked. It means that we have to return first to rework the die construction by changing the critical die parameters (e.g. die radii, drawing gap, etc.). If it does not solve the problem, a new die design, or a new process planning is required. Some cases, we have to go back even to the product design stage to modify the product parameters. The more we go back the higher the development and design costs are. Occasionally, the die set is scraped and a perfectly new product-, process- and die design is needed. As a result, die manufacturing time is increased as well as the cost of die making. 3. Process planning and die-design in sheet metalSimulation and Knowledge Based Systems An Integrated ApproachAs it was mentioned before, this solution will be described through the example of an automotive sheet metal component using the Unigraphics NX (version 4.0) as the CAD system, and the AutoForm 4.05 as the FEM package, however, the principles applied here, can be adopted to other programs as well 10. The selection of these two program packages can be explained by several reasons. On the one hand, both the Unigraphics and the AutoForm are among the most widely applied packages in the automotive industry in the World. On the other hand, these two systems are among the first to offer a special interface module to enhance the information and data exchange between CAD modelling and FEM simulations in both directions making possible the most efficient integration during the whole product development cycle. In the forthcoming sections, this solution will be described in detail following the road map of this simulation-guided process planning and die design procedure. 3.1.Geometric modelling of the sheet metal componentThe CAD model of the component created by the product design engineer is shown in Fig.3. As it often happens in the automotive industry, the component has a symmetric counterpart (so-called left and right handed or double attached parts). The part model is created in Unigrapics NX 4.0 CAD system as a solid model. However, FEM systems dedicated for sheet metal forming usually require surface models. Therefore, before exporting the part model a surface model should be created. This function is well-supported in most CAD systems. Depending on the simulation requirements, even we can decide which surface (top, middle or bottom) will be exported into the surface model. 3.2.Feasibility of the component formabilityIn most cases, process planning engineers would like to know right at the beginning whether the component can be manufactured with the planned formability operations. Therefore, after importing the surface model of the component with the AutoForm input generator, first a fast feasibility study should be performed. The AutoForm has an extremely well suited module for this purpose: in the so-called One-Step simulation module, this formability analysis can be done even if we do not have any or just very few information on the forming tools. Using this One-Step simulation procedure, a quick decision can be made if any modification of the part is required. Besides the part formability validation in this very early stage of product development, further important possibilities are also offered in this module including the analysis of slight part modifications, studying alternative material types and grade, or various thicknesses, material cost estimation and optimization, etc. If this feasibility study is successful as shown for example for this component in Fig.4, the work of process planning engineer can be efficiently supported by determining the optimum blank shape and sizes. 4. ConclusionsComputer aided engineering has a vital and central role in the recent developments in sheet metal forming concerning the whole product development cycle. The application of various methods and techniques of CAE activities resulted in significant developments: the formerly trial-and-error based workshop practice has been continuously transformed into a science-based and technology driven engineering solution. In this paper, an integrated approach for the application of knowledge based systems and finite element simulation is introduced. Applying this knowledge and simulation based concept for the whole product development cycle from the conceptual design through the process planning and die design as an integrated CAE tool provides significant advantages both in the design and in the manufacturing phase. Sheet metal forming simulation results today are already reliable and accurate enough that even tryout tools and the time consuming tryout processes may be eliminated or at least significantly reduced. Thus, the integrated solution described in this paper results in significantly shorter lead times, better product quality and as a consequence more cost-effective design and production.AcknowledgementsThis research work was jointly financed by the Hungarian Academy of Sciences (MTA) and the National Science Foundation (Ref. No.: OTKA NI 61724). This financial support is gratefully acknowledged. References1 S.K. Sitaraman, T. Altan, A Knowledge Based System for Process Sequence Design in Sheet Metal Forming, Journal of Materials Processing and Technology (1991) 247-271. 2 N. Alberti, L. Cannizaro, F. Micari, Knowledge Based Systems and FE Simulations in Metal Forming Processes, Annals of CIRP 40 (1991) 295-298. 3 L. Eshelby, M. Barash, W. Johnson, A Rule Based Modelling for Planning Axisymmetric Deep-drawing, Journal of Mechanics Sciences (1988) 1-113. 4 A. Makinouchi, Sheet Metal Forming Simulation, Journal of Materials Processing and Technology 60 (1996) 19-26. 5 A.E. Tekkaya, State of the art of Simulation in Sheet Metal Forming, Journal of Materials Processing and Technology 103 (2000) 14-22. 6 T. Altan et al., Simulation of Metal Forming Processes, Proceedings of the 6th International Conference ICTP, Nuremberg, 1999, 23. 7 M. Tisza, Numerical Modelling and Knowledge Based Systems in Metal Forming, Advanced Technology of Plasticity 1 (1999) 145-154. 8 A. Andersson, Information Exchange within Tool Design and Sheet Metal Forming, Journal of Engineering Design 12 (2001) 283-291. 9 A. Andersson, Comparison of Sheet Metal Forming Simulation and Try-out Tools in Design of Forming Tools, Journal of Engineering Design15 (2004) 551-561. 10 M. Tisza, Numerical Modelling and Simulation: Academic and Industrial Perspectives, Materials Science Forum 473-474 (2005) 407-414. 近年来计算机辅助工艺规划和板料成形数值模拟过程米蒂萨河*制造和加工摘要目的:本文:在最近的10 - 15年,计算机辅助工艺设计及模具设计的进化成为其中一个最重要的工程工具板料成形过程中,特别是在汽车工业。这一新兴的角色是强烈的迅速发展,强调了有限元模型。本文的目的是给出一个概述,关于近年来所取得的成就在非常重要的板料成形领域,介绍一些在这个发展活动中的特殊结果。设计/方法/途径:对板料成形 CAE 活动,主要有两种方法:其中一个可能被看作是基于知识的工艺设计,而另一个基础工艺规划为仿真。作者试图通过商业CAD 系统和有限元方法整合这两个独立发展的基础知识和仿真方法。结果:应用上述方法一个更强大、更高效的工艺设计及模具设计的解决方案可能达到彻底降低芯片制造时间和费用,降低产品开发周期,提高产品质量的效果。研究局限性/含义:由于有限元方法和 CAD 系统不同的造型方法 ,最大的挑战是提高数据交换能力较强的鲁棒性之间的不同系统以提供一个更精简的信息流动。实际应用:该综合解决方案对于提高板料成形过程中很重要的工业环节的全球竞争力有重要的现实意义。创意/价值:本文中介绍的概念对于工艺设计及模具设计工程师都可能有特定价值。关键词:分析和模型;基于知识和仿真系统。1.介绍近年来成型过程的作用与重要性在制造业中不断增加,主要由于其材料和精打细算的性质。这是进一步强调了近年来的工具、材料和设计,从而提供显著的改善力学性能及公差的产品。它也是对金属板料成形特点中最后形成的组件不能由一般生产的一次手术,但是更常见的几种手术应把初始简单的几何变换成一个更复杂的产品。此外,近年来在金属成形的方向发展分析钣制带轮近净减少或制备生产需要后续加工操作,并尽量避免妨碍总生产成本。因此,金属成形工艺设计和工具设计代表了一个非常重要且复杂的任务。全球竞争也需要制造业,除了在商店实践的技能和经验积累,也应该越来越利用电脑辅助工程实践技术的快速和低成本的工艺设计和工具制造。应用多种多样的计算机辅助工程已成为最重要的课题之一,特别是在制造业的汽车工业。各行各业的 CAE 技术应用几乎涵盖了从产品概念设计到工艺设计及模具设计到制造阶段的生产的全部产品开发周期。CAE 技术广泛应用于板料成形,预测,确定型号序列参数和生产流程,设计成形模具,等。应用 CAE 技术对于制造日益复杂的工具零件的重要性越来越大。因为需要 CAE 技术的广泛应用来加速推动全球竞争力,需要一个良好的鲁棒性和流线型的过程和模具设计工程(PDDE)变得越来越重要。最近,有两个主要的方法来实现这些目标。其中一个是基于知识的专家系统的应用,这通常是基于简化塑性理论和实证技术规则。将会有非常大量的文件处理知识系统专用权都和大量的金属成形板材1 - 3。然而,专门为以知识为基础的解决方案有一定的缺点:他们通常无法提供足够精确的解决这个问题的方法,因为这些系统通常基于简单的技术规则和限制的有效性。因此知识系统无法预测例如物流,而且通常不能提供准确的应力和应变分布在组件。作为另一个方法,数值方法(主要是有限元模型)被广泛应用于分析塑性变形4 - 6。应用的主要目的数值模拟在金属成形过程中,确定合适的工艺参数和提供足够的模具设计过程仿真,提高产品的质量,防止被预测的工艺范围流激缺陷。除了这些,也会通过数值过程模拟减少工艺、模具选拔以及交货周期,同时大大降低制造成本。但独家使用数值模拟的研究 就象它是这个案子独家使用知识系统,也有一些弊端,也具有一定的参考价值。尽管硬件和软件设施快速发展,其可靠性结果也往往取决于用户的经验。其中一部分是由于大量的操作参数的影响需进行调查,另一部分是由于应用数学模型描述材料的行为造成数值困难的复杂性。因此,在近年来的整合这两个领域(如知识系统和数值模拟)的研究已获得了重要进展7。2.工艺设计和 die-design 金属片一个主要的缺点在工业实践阻碍更广泛应用仿真技术,输出结果的模拟软件包通常不直接和容易使用计算机辅助模具设计。显然,还要有巨大的努力去成功连接计算机辅助设计和有限元系统,但是,在这一领域仍然有很多事情需要做 8。这就需要一个完全集成的方法计算机辅助产品设计,工艺设计和模具设计,以及有限元模拟形成过程。这意味着仿真工具应该被有效的利用整个产品开发周期9。这一概念将通过实例的汽车零件生产。在实践中,我们使用 Unigraphics NX 的4作为商业 CAD 系统支持计算机辅助工艺设计及模具设计的任务、AutoForm 4.05和 PAM-STAMP 2 G 作为数值模拟工具,然而,采用的原则在这里同样可以通过使用不同的计算机辅助设计与仿真软件包。在分析这种综合的解决方案,让我们总结形成过程规划的主要特点及模具设计在所谓的传统 CAD 环境。2.1.传统 CAD 环境中的工艺设计及模具设计冲压行业应用计算机辅助设计技术在工艺设计和模具设计已经很多年了。然而,在传统的环境,这些几乎是独立的解决方案,即例如基于知识的工艺规划的解决方案是用于确定必要的类型的形成过程中,甚至在某些情况下,形成序列也可以用这种方法连同适当的过程 paramteres。在确定过程中的序列和工艺参数,成形模具的设计采用了先进的计算机辅助设计系统,然而,我们仍然没有任何证据是否设计的工具将提供部分规定的特性。因此,在它的生产线,通常是一个时间和成本消耗,试行阶段如下,显示图1。如果试验是成功的,即模具生产零件没有冲压缺陷,它将被发送到冲压厂生产。另一方面,如果分裂或起皱发生在试模,模具需要重做。这意味着我们必须返回第一返工的模具结构改变的关键参数(如模具模具半径,模具间隙,等。 ) 。如果不解决这个问题,一个新的模具设计,或一个新的工艺规划是必要的。某些情况下,我们必须返回到产品设计阶段的产品参数修改。我们越回较高的开发设计成本。偶尔,模具刮和一个完美的新产品,工艺和模具的设计是必要的。因此,模具制造时间增加以及成本的模具制作。3.仿真和基于知识的系统综合方法就像前面提到的,该方案将通过一个例子:汽车钣金部件使用 UG(4版)为计算机辅助设计系统,AutoForm 4.05为有限元分析软件包,然而,这个原则应用在这里,也可以用于其他方案10。这两个项目的选择软件包可以解释为几个原因。一方面,这两个 UG 和AutoForm 是最广泛应用的软件包在世界汽车工业。另一方面,这两个系统是最早提出一项特殊的接口模块,提高信息和数据交换之间的建模和数值模拟两个方向可能是最有效的整合在整个产品开发周期。在即将到来的部分,这个方案将被用来详细描述 simulation-guided 地图的工艺设计及模具设计过程。3.1.金属板材的几何造型的组成部分先进的 CAD 模型的组成由产品设计工程师被显示在图。因为它常发生在汽车行业、组件都有一个对称的对手(所谓的左、右撇子或双附件)。部分模型 Unigrapics NX 创造4.0 CAD 系统作为一个实体模型。然而,专用有限元板料成形系统通常需要表面模型。因此,在出口前部分模型表面模型应该被创造出来。这个函数是良好的支持在大多数 CAD 系统。根据仿真需求,即使我们可以决定哪些表面(上层、中层或底部)将被出口到曲面模型。3.2.部分成型的可行性在大多数情况下,工艺设计工程师想知道部件可以开始生产的成形性与计划行动是否正确。因此,在引进曲面模型的输入组件 AutoForm 发电机,首先应进行快速的可行性研究。这 AutoForm 有极适合模块为这个目的:在所谓的一步法仿真模块,该成形性能做了分析,即使我们没有任何信息或者只是很少的形成的工具。使用这个一步仿真程序,一个快速的决定,可以做任何修改的部分是必需的。除了部分成形性能验证在这个早期阶段的产品开发,更重要的可能性也提供在本模块包括分析细微部分修改,研究替代材料的类型和等级,或不同的厚度,材料成本的估算和优化,等。如果这个可行性研究是成功的,如图所示,例如该组件图工艺规划工程师的工作,可以有效地支持确定最佳毛坯形状和尺寸。4.结论在金属板料成形的整个产品开发周期中计算机辅助工程具有重要的核心作用并且扮演着重要的角色。应用 CAE 各种方法和技术的活动产生重大进展:以原试车间实践为基础一直不断转化为科学和技术驱动的工程解决方案。本文提出了一个综合的方法的应用,以知识为基础的系统和有限元模拟方法。应用这些知识和仿真的基础概念,为整个产品开发的周期,从概念设计到工艺设计及模具设计为一体的 CAE 工具,具有明显的优势,无论在设计和制造阶段。今天的金属板料成形模拟结果已经足够精确可靠,甚至调试工具和耗时的调试过程可能被取消或至少显著降低。因此,本文描述的综合解决结果显著地缩短交货期,提高了产品质量,因而更具成本效益的设计与生产。鸣谢这项研究工作是由匈牙利科学研究院(中国)和美家科学基金会(参考编号:otka 镍61724)共同出资。对这种财政支持表示感谢。参考文献1 S.K. Sitaraman, T. Altan,一个基于知识的系统的工艺流程设计在板材成型过程中,材料加工技术杂志(1991)247-271。2 N. Alberti, L. Cannizaro, F. Micari,基于知识的系统和有限元模拟金属成形过程中,志40(1991)295-298。3 L. Eshelby, M. Barash, W. Johnson,一个以规则为基础的模拟规划轴对称拉深,力学学报科学(1988)1-113。4 A. Makinouchi,板料成形模拟,材料加工技术杂志,60(1996)19 - 26。5 A.E. Tekkaya,国家艺术的仿真技术在板料成形,材料加工技术杂志,103(2000)14 - 22。6 T. Altan et al.,模拟金属成型过程,第六届国际会议国际理论物理中心,纽伦堡,1999,23。7 M. Tisza,数值模拟,基于知识的系统在金属成形,工艺先进的可塑性,1(1999)145-154。8 A. Andersson,信息交换的工具设计和钣金成形,工程设计学报12(2001)283-291。9 A. Andersson,比较钣金成形模拟及试验工具成型刀具的设计,工程杂志(2004)551-561design15 。10 M. Tisza,数值模拟与仿真:学术和工业的角度来看,材料科学论坛 473-474(2005)407-414。
收藏