复杂环境下汽车冲压件回弹的准确计算分析

项目名称： 复杂环境下汽车冲压件回弹的准确计算分析

项目编号： No.11472072

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 数理科学和化学

项目作者： 赵坤民

作者单位： 大连理工大学

项目金额： 75万元

中文摘要： 金属板材冲压成形是应用十分广泛的一种塑性成形技术，冲压成形的数值仿真已被广泛使用，但随着仿真在工程应用中进一步深入，现有技术的局限性开始暴露出来，不能准确计算复杂环境下冲压件的回弹。本项目旨在揭示当前有限元法不能准确模拟三种复杂环境下冲压成形及回弹的原因，并通过构建准确模拟金属板材接触小圆角模具表面并滑动的大塑性变形计算力学模型、构建含有子结构的冲压仿真有限元模型、以及计算回弹过程中动力显式算法与静力隐式算法多步骤自动切换等手段，来准确模拟0.3 mm以下的轻微表面塌陷问题、含拉延筋大冲压件的拉延回弹问题、以及小模具圆角的翻边回弹问题。复杂环境下冲压成形及回弹的数值模拟涉及到诸多计算力学难题，这些问题是数值模拟制造过程的共性基础科学问题，有效解决此类问题有助于推进计算力学在制造领域中的应用，为实现新一轮工业革命里的核心技术，即制造业的数字化智能化，奠定科学基础。

中文关键词： 计算力学；有限元分析；数值模拟；工程力学；车辆工程

英文摘要： Sheet metal stamping is a widely applied plastic forming technology. Numerical simulation has been used to aid stamping process design, die engineering and problem solving. However, with further and deeper application, the limitations of the current simulation technology surfaced up, namely, it cannot accurately or even correctly calculate the springback under complex stamping environment. The proposed project aims to build an accurate large plastic deformation computational mechanics model for sheet metal contacting with and sliding over small die radius, to build a stamping simulation model with substructures, and to develop a seamless multi-step automatic switching scheme between dynamic explicit algorithm and static implicit algorithm during springback calculation. These methods will help accurately simulate the less than 0.3 mm surface distortion problem, and calculate the springback of large drawn panels with drawbead and the springback of flanging over tight die radius. Simulation of stamping and springback under complex environment involves many aspects of computational mechanics. These aspects reflect the common fundamental scientific problem facing simulation of manufacturing processes. An effective solution to this problem will help advance the application of computational mechanics into manufacturing, and help establish scientific foundation for the core technology of the forthcoming new round industrial revolution, i.e. digital and intelligent manufacturing processes. For stamping alone, accurate simulaiton of springback relates domestic eight billion yuan annual cost for die manufacturing and product quality. So this project has an important economic value besides scientific significancy.

英文关键词： Computational Mechanics;Finite Element Analysis;Numerical Simulation;Engineering Mechanics;Automotive Engineering