基于正交试验的铝钢材料自冲铆接成形质量的多指标优化

以某汽车上材料厚度分别为1 mm的6016铝合金与1.5 mm的ST13结构钢的自冲铆接作为研究对象,借助正交试验设计方法,利用Deform-2D数值模拟软件,对6016/ST13铝钢异种材料自冲铆接成形质量的多指标进行了工艺参数优化。以模具宽度、模具凸台高度和模具深度作为正交试验的影响因子,以剩余厚度、底切量以及钉头高度作为正交试验的评价指标。利用矩阵分析法对正交试验的结果进行分析,得出6016/ST13铝钢自冲铆接的最优方案为:模具深度为1.5 mm、模具宽度为9 mm以及模具凸台高度为0 mm,剩余厚度、底切量以及钉头高度的模拟值分别为0.487,0.602与0.059 mm。利用自冲铆接设备及安装模具对优化方案进行试验验证,剩余厚度、底切量与钉头高度的有限元模拟值与试验值之间的相对误差分别为12.12%,8.97%与13.56%,从而验证了正交试验及有限元模拟应用于铝钢异种板材自冲铆接成形工艺参数优化的正确性。

Multi-index optimization on forming quality of self-piercing riveting for aluminium-steel materials based on orthogonal experiment

For self-piercing riveting of 6016 aluminium alloy with the thickness of 1 mm and ST13 structural steel with the thickness of 1.5 mm in an automobile,the multi-index of forming quality for self-piercing riveting of 6016/ST13 aluminium-steel dissimilar materials was optimized by the orthogonal experiment design and numerical simulation software Deform-2D.Then,taking die width,height of die convex and die depth as the influencing factors and the remaining thickness,under-cut and head height as the evaluation indexes,the results of orthogonal experiment were analyzed by matrix analysis,and the optimum scheme of self-piercing riveting for 6016/ST13 aluminum-steel was obtained with the die depth of 1.5 mm,the die width of 9 mm and the height of die convex of 0 mm.Furthermore,the simulated values of remaining thickness,under-cut and head height were 0.487,0.602 and 0.059 mm respectively.Finally,the optimum scheme was tested by riveting equipment and installation die,and the relative errors of remaining thickness,under-cut and head height between simulation and experimental values were 12.12%,8.97%and 13.56%respectively.Thus,the correctness of orthogonal experiment and finite element simulation applied to the optimization of process parameters for self-piercing riveting of aluminium-steel dissimilar sheets was verified.