汽车尾灯支架装配变形的数值模拟与验证

目的 深入研究汽车尾灯装配变形，建立可以精确预测尾灯装配变形的有限元方案。方法 通过数字图像相关法研究了尾灯紧固过程中钣金支架的变形情况，获得了支架上关键位置的变形规律。引入有限元仿真分析方法，建立了全工况有限元仿真分析模型，对尾灯装配的整个过程进行数值仿真。结果 获得了装配后钣金变形量的预测值，通过对3类尾灯的装配过程进行仿真分析，对比实际测量的钣金支架变形数据，验证了该模型能够较为精确地预测尾灯装配中的变形误差。结论 提出了尾灯装配定位基准与螺栓紧固点分离的解决方案，从设计上有效避免了新车型尾灯装配超差问题的产生。

Numerical Simulation and Experimental Verification of Assembly Deformation of Automobile Tail Lamp Sheet Metal Bracket

The tail lamp assembly deformation is deeply studied, and the finite element scheme which can accurately predict the tail lamp assembly deformation is established. Through the digital image correlation method, the deformation of the sheet metal bracket during the fastening process of the tail lamp is studied, and the deformation law of the key position on the bracket is obtained. The finite element simulation analysis method is introduced to establish the full condition finite element simulation analysis model. The numerical simulation of the whole process of tail lamp assembly is carried out, and the predicted value of sheet metal deformation after assembly is obtained. Through the simulation analysis of three types of tail lamp assembly process, compared with the actual measured deformation data of sheet metal bracket, the model can accurately predict the deformation error of tail lamp assembly.On this basis, the solution of separating the tail lamp assembly positioning datum from the bolt fastening point is further proposed, which effectively avoids the problem of out of tolerance in the new model tail lamp assembly.