基于CAE某型汽车发动机前罩壳冲压模设计

基于机械优化设计的思想,通过对冲压件前罩壳的分析,建立了符合要求的模型.运用Dynaform软件进行CAE分析.由于引入了CAE,冲压成形已从原来的对应力应变进行分析而逐步发展到采用有限元等进行工艺过程的模拟与分析,实现了冲压过程的优化设计.     

基于CAD/CAE技术的机械设计和模具设计

随着社会经济水平的不断提高和工业规模的不断扩大,我国对机械和模具设计提出了更高的要求,旨在保证机械产品的功能完善性,这无疑加大了对机械产品和模具产品的加工难度,甚至还增加了这些产品的生产成本,为了解决以上问题,现提出一种新型、先进的CAD/CAE技术,以实现对机械和模具的科学设计,为促进机械产品和模具产品的健康、可持续...     

某模具结构的设计与加工工艺探讨

改进动模具结构采用了型腔四周环绕冷却水路和型芯鸭舌水路解决了冷却不充分和粘定模等问题。本文经某模具结构及成型工艺分析,优化了浇注系统和模具结构,降低了模具制造成本。实践证明,模具结构合理,动作平稳、可靠,能较好地满足要求,对类似的模具设计有一定参考价值。     

基于CAD／CAE／CAM技术的注塑模具课程设计的改革

通过CAD／CAE／CAM综合实践,使学生了解和掌握基本的产品设计、制造一体化过程。学生通过完成项目而把理论与实践有机地结合起来,提高理论水平和操作技能。     

加强板翻边模具结构设计及工作过程的探究

加强板翻边成形对于产品的生产质量和生产效率至关重要,本文笔者结合具体案例,在分析加强板翻边成形工艺和工作原理的基础上,对加强板翻边模具工作过程进行了深人的探讨,结果表明所设计的翻边成形工艺方案切实可行,具有较高的参考价值。     

前围外板的冲压工艺设计及成形分析

目的解决汽车覆盖件因为冲压变形复杂,成形工艺参数难以确定的问题。方法分析了汽车前围外板的成形工艺,研究了复杂型面拉深模具的型面设计,以有限元分析软件AUTOFORM为平台,对其冲压成形过程进行了数值模拟。根据模拟结果(成形极限图、材料流动分布及材料变薄率)对拉延型面及工艺参数进行了优化。结果所得零件材料最大减薄率为17.3%,在SPCE(t=0.8 mm)材质减薄率安全范围内(18.7%),消除了成形过程中的暗伤开裂风险,成形结果得到了大大改善。结论 CAE仿真能够预测零件成形过程中存在的缺陷,优化工艺参数,指导模具设计工作。将优化结果用于指导实际生产,得到了符合质量要求的拉延零件。     

基于CAE的大型LCD注塑面板变模温设计与分析

研究了一种利用蒸汽加热和冷却水冷却的变模温注塑工艺,制定了其工艺流程.以LCD面板为例,通过构建变模温注塑工艺分析模型,利用ANSYS对其加热、冷却过程进行了数值模拟,研究了加热、冷却过程中型腔表面和聚合物熔体的热响应规律,为优化变模温注塑工艺参数提供理论依据.最后,通过构建LCD面板变模温注塑实验生产线,并将分析结果应用于实验生产,验证了模拟分析的有效性和准确性.结果表明,利用本工作提出的变模温注塑工艺,可在不降低生产效率的同时,彻底消除塑件表面熔接痕和提高塑件表面光泽度.     

快速模具技术在304板材液压成形中的应用

先进快速制模技术是近年来模具制造业中十分活跃的领域之一,尤其在汽车车身试制行业,正得到越来越多的关注.主要针对与美国GM公司合作的快速模具与板材液压成形相结合的柔性成形项目进行了相应的试验研究,利用电弧喷涂Zn合金,并加以树脂做背衬的快速模具,尝试了软凸模液压成形直边带有较为复杂曲底面的浅杯形件的工艺研究,并对成形过程利用Dyna-form软件包进行了有限元模拟分析.研究表明,使用快速制模技术和液压成形技术成形304板材复杂浅杯形件,其成品具有较高的精度,且成形条件不复杂,可以推广.     

基于数值模拟的管材平面弯曲成形几何加工精度规律

目的 建立高精度的有限元仿真模型可以有效地指导实际加工生产,在减少实验成本及结构件制造开发周期的同时提高成形效率。提高数值模拟中金属管材平面弯曲成形的几何加工精度,同时探究关键工艺参数对几何精度的影响规律,确定最佳工艺参数组合。方法 以管材平面弯曲成形构件为研究对象,建立了基于自由弯曲技术的管材弯曲成形有限元仿真模型,并通过实际加工实验验证了仿真精度,随后针对仿真模型的几何误差进行了参数补偿。将使用较高精度的仿真模型模拟得到的数据作为数据来源,研究关键工艺参数对仿真成形几何精度的影响机制,采用熵值法确定最佳工艺参数组合。结果 通过实际成形实验对比分析,在不同成形条件下,有限元仿真结果与实际加工结果高度吻合,两者之间的加工误差不超过2%,针对规格为32 mm×2 mm的20号碳钢管材,当轴向推进速度为5 mm/s,管材与弯曲模间隙值为0.25 mm时加工精度最高。结论 优化改进后的有限元仿真模型具有较高的几何成形精度,可有效指导实际成形工艺参数的优化工作。     

A methodology for evaluation of metal forming system design and performance via CAE simulation

In the current metal forming product development paradigm, product cost, time-to-market and product quality are three overriding issues, which determine the competitiveness of the developed products. In the up front design process, the first 20% of design activities commits to about 80% of product development cost and product quality issues. How to conduct ‘right the first time’ design is critical to ensure low development cost, high product quality and short time-to-market. To address these issues, state of the art technologies are needed. Traditionally, computer-aided design (CAD) and computer-aided manufacturing (CAM) technologies provide solutions for representation of design intent and realization of design solution physically. However, it is difficult to address some critical issues in the design of forming process, tooling structure, material selection and properties configuration, and finally the product quality control and assurance. Computer-aided engineering (CAE) technology fills this gap as it helps practitioners generate, verify, validate and optimize design solutions before they are practically implemented and physically realized. In this paper, a methodology for evaluation of metal forming system design and performance via CAE simulation is developed. The concept of metal forming system and its design is first articulated and how the CAE technology helps design and design solution evaluation is then presented. To assess and evaluate the performance of metal forming systems, quantitative design evaluation criteria are developed. Through industrial case study, how the developed methodology helps metal forming system design and evaluation is illustrated and its efficiency and validity is finally verified.     

Estimating machining-related energy consumption of parts at the design phase based on feature technology

To overcome the difficulties in previous researches about energy-efficient design of parts, a method to estimate machining-related energy consumption of parts at the design phase is proposed. The binary tree is constructed to describe the structure of a part, and each node in the binary tree represents one feature in the part. The material embodied energy, theoretical cutting energy consumption and air-cutting energy consumption of a feature can be calculated based on its design and manufacturing parameters. At the design phase, manufacturing parameters of a feature can be obtained by the method of feature mapping from design parameters. By adding up above three types of energy consumption, total energy consumption of a feature can be calculated. Further, by adding up total energy consumption of all features in a part, the energy consumption of this part can be estimated. The proposed method was demonstrated by estimating the energy consumption of a shaft part designed by an auto parts manufacturer, and meanwhile the measured energy consumption of the shaft part was acquired by experimental measurement. The estimation accuracy is analysed and verified by comparing the estimated value and measured value.     

基于模具预先补偿法的大幅面CFRP制件形状精度控制方法

针对控制大幅面CFRP制件成型后的形状精度这一关键技术问题,在剪切层法预测变形的基础上提出了一种改进的剪切层变形模拟方法。改进的方法只需少量制件实验数据,通过计算应变曲线曲率确定剪切层厚度,进而较准确地预测了CFRP制件的翘曲变形。基于变形模拟方法建立了一种大幅面CFRP制件形状精度控制方法,这一方法通过将模拟获得的变形不断补偿于初始模具型面来降低最终制件的变形。通过与实验数据的对比,证明了采用控制方法可以有效提高成型制件的精度,降低变形。     

CAD／CAE及其在机械产品研发中的应用

计算机的发展和广泛应用给机械科学带来了革命性的变化，以虚拟样机为代表的CAD／CAE是其在设计中的具体体现，本文从机械产品研制的角度出发，阐述了CAD与CAE的关系，虚拟样机技术的内涵，总结了有限元法和虚拟样机技术在机械产品设计研究中的应用情况，并指出了目前国际上虚拟样机的研究重点。     

板料渐进成形数值模拟与实验研究

为提高渐进成形的成形效率和成形质量,了解板料渐进成形的变形规律及工艺参数对成形的影响,采用有限元方法对板料渐进成形过程进行了数值模拟研究,分析了斜壁盒形件渐进成形过程应力分布和厚度变化趋势,通过对不同进给量和不同成形路径进行数值模拟,分析了工艺参数对成形的影响.结果表明,斜壁盒形件最大应力和最大厚度减薄发生在底面拐角处;成形过程中工具头运动轨迹应尽量采用走螺旋线的方式,可以提高成形件的成形能力和成形质量.渐进成形实验表明,数值模拟结果与实验结果基本吻合.     

模具工业先进制造技术特点及发展概况

重点介绍模具CAD/CAE/CAM集成化、现代模具检测与加工设备,新型模具材料及表面处理技术、快速经济制模技术等模具先进制造技术的发展特点;分析探讨了模具工业的新的制造哲理与模式。     

Multidisciplinary design process based on virtual prototyping for microsystem design

Microsystem design involves the mixing of two main disciplines: mechanical engineering and electronics. Multidisciplinary design approach is not easy to implement and becomes more difficult when the challenge consists in simultaneously handling new knowledge that characterizes the field of microsystem industry. We present herewith a new multidisciplinary engineering approach used to lead the detailed design of micro-accelerometers based on virtual tools. Virtual prototyping that is usually implemented in one sole domain of competence is developed to be manipulated by either experts from electronics or mechanics. This new tool improves collaboration and the rapid identification of highly satisfying solutions. The virtual tool allows exploration of micromechanical devices and system design issues and objectives. It uses interactions with the designer in order to achieve solutions integrating the physics rules of the design and the experience of the designer.     

基于支持向量机和重要度抽样的高强度钢板冲压成形工艺稳健设计

高强度钢板成形中噪声因素的存在造成了冲压质量不稳定.提出了基于支持向量机和重要度抽样的板料成形工艺稳健设计方法,量化了噪声因素对成形质量的影响,同时结合优化算法求解即满足质量可靠性又保证质量目标最优的工艺条件.对一高强度钢板冲压实例进行了工艺优化.按优化工艺冲压成形的零件减薄率及回弹均有所改善,验证了该方法的有效性.     

基于结构谐振CAE分析的注塑机械手优化设计

注塑机械手是对塑料加工生产进行自动控制的生产设备.在实际工作过程中,注塑机械手在快速响应的控制条件下会产生结构谐振,影响机械手的定位精度.应用参数化建模方法和CAE软件对注塑机械手进行结构谐振有限元分析,并基于多学科优化设计平台,以减小谐振为目标,采用自适应模拟退火算法对机械手的结构尺寸进行优化设计,最终降低了机械手平台振动,提高了机械手的定位精度,并实现了设计优化过程的自动化,为类似产品的设计开发提供了系统的参考方法.