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摘要车用铝合金由于质量较轻的特性如今在车辆制造方面所占比重也越来越大，然而由于铝合金板材的冲压成形过程中应力情况较为复杂，为了优化冲压工艺，确保成型质量，必须充分研究板材冲压性能。本文以汽车常用6000 系铝合金为研究对象，通过试验研究和有限元模拟，对其冲压成形性能进行研究。主要完成的工作如下： （1）通过拉伸试验测定了车用铝合金的各项力学性能参数。 （2）通过Nagazima 试验结合数字图像相关方法获得材料的成形极限曲线 FLC，分析了该材料在常温下的成形极限状态，并分析了试验失效原因和解决方法。 （3）对有限元仿真方法预测出材料的成形极限曲线与试验结果进行了对比，并对误差进行分析。结果表明，有限元分析与试验结果符合度较好，有限元分析结果可以指导实际的工程应用。 （4）自主设计加工了一套凸模胀形加载装置。该装置可以方便有效地用于薄板的FLC 测定试验。 42039
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毕业论文关键词 车用铝合金 成形极限 有限元模拟 数字图像相关方法
Title FEM simulation and experimental study on stamping forming performance of Aluminum Alloy for automobile
Abstract Due to the lighter weight of the Aluminum Alloy for automobile, it is used widely in automobile manufactory fields nowadays, however due to the complexity of the stress field occupied in forming process, the forming properties should be fully analyzed to guarantee the forming process quality. In this paper, the stamping forming capability of 6000 series aluminum alloy was investigated by experiments and finite element method simulating. The main results are as follows: (1)The mechanical parameters of 6000 series aluminum alloy were determined by tension experiment. (2)The FLC (Forming Limit Curve) of this material was obtained by combining Nagazima experiment and DIC(Digital Image Correlation) method .The reasons of experiment failures were analyzed and solution to overcome the failures were put forward. (3)The FLC curves from the FEM simulation and the experiment methods were compared and the errors were analyzed . It was showed that the data from the FEM fitted those from the experiment method and it is clearly that the results from the FEM simulation can be used to direct the stamping forming processes. (4)A loading device for FLC testing was designed and manufactured, which can be easily and efficiently applied on testing metal sheets’ FLC experiments.
Keywords Aluminum Alloy for automobile FLC(Forming Limit Curve) Finite Element Simulation Digital image correlation method
目次
1引言1
1.1研究背景及意义1
1.3本文的研究目的与主要内容...2
2金属冲压成形性能及参数..3
2.1金属板料成形性能的概念...3
2.2铝合金薄板冲压成形性能参数...4
3.1试样制备9
3.2试验装置..12
3.3试验过程..17
3.4试验结果..19
3.5本章小结..25
46000系铝合金有限元模拟...26
4.1有限元模拟方法及模型.26
4.2本章小结..34
结论.36
致谢.37
参考文献...38
1 引言 1.1 研究背景及意义 近二十几年来，能源和安全已经变成阻碍全球汽车行业发展的严峻问题。发展汽车技术也是围绕着这两方面进行的，而能源问题最为突出。汽车轻量化的意义为在保证汽车的安全性能和使用强度的前提下,尽可能地降低汽车的质量,以便于减少燃料的消耗,从而降低排气污染。研究显示,车辆每减重100kg,二氧化碳排放量可减少月 5g/km3，且能够有效节省燃油，因此，为了有效的节约自然资源，减少对大气的污染，汽车轻量化迫在眉睫[1]。 铝合金作为汽车轻量化的首选材料，具有很多良好的材料性能，如耐蚀性强，强度高。但是相较于钢而言，铝合金在常温下的成形性能比较差，材料的延伸率低，且由于弹性模量较低，在冲压过程中难以控制精度。因此对于铝合金冲压成形性能的研究成为亟待解决的问题。