异质滚合结构固化变形预测及曲面重构预补偿方法

doi:10.16183/j.cnki.jsjtu.2021.225

摘要/Abstract

摘要：

异质材料结构兼具成本和性能优势,是新一代车身门盖件轻量化的重要手段.但板材物理特性差异和胶材料属性的复杂变化,易导致结构固化失配变形.为消除结构变形,提出变形预测与曲面重构预补偿方法.构建循环温度载荷下的热-化学-结构耦合场预测模型,考虑折边胶在全固化周期内材料特性转变的影响,包括固化度、化学缩变和应力松弛.以典型铝/钢薄板曲边滚合结构为研究对象,仿真分析多物理场固化过程,对铝合金外板变形量进行预测,并利用非接触式数字图像相关法测量实验进行验证.对固化变形进行几何补偿,对比分析约束方向、连线方向和法线方向补偿的效率,并实验验证方法的可靠性.研究表明:与传统黏弹性模型相比,构建的多物理场耦合模型能够更准确地反映异质滚合结构高温固化变形;基于非均匀有理B样条曲面重构的几何补偿法能够有效降低结构固化变形;法线方向补偿法的效率更高.研究结果为新一代异质车身门盖件制造精度的提升和工艺优化提供了重要参考.

关键词: 异质滚合结构, 固化变形, 多物理场, 几何补偿, 曲面重构

Abstract:

Dissimilar material structure has the advantages of both cost and performance, and has become an important means of lightweight for the new generation of autobody closure panels. However, the difference between physical properties of sheets and the complex change of adhesive material properties are easy to lead to structural curing mismatch deformation. In order to eliminate the structure deformation, a method for deformation prediction and surface reconstruction pre-compensation was proposed. Then, considering the material property transformation effect of curing degree, chemical shrinkage, and stress relaxation, a thermal-chemical-structural field coupled model for high temperature curing of hemming adhesive was established. Taking the typical aluminum/steel sheet curved-edge hemming structure as the research object, the multi-physics field curing process was simulated and analyzed, and the deformation of aluminum alloy outer panel was predicted, which was verified by non-contact measurement experiment using digital image correlation (DIC) method. Finally, the geometric compensation of curing deformation was conducted, the compensation efficiency of constraint direction, connection direction, and normal direction was compared and analyzed, and the reliability of the method was verified by experiment. The results show that compared with the traditional viscoelastic model, the multi-physics field coupling model can more accurately reflect the high temperature curing deformation of hemming structures with dissimilar materials. The geometric compensation method based on non-uniform rational B-splines (NURBS) surface reconstruction can effectively reduce the curing deformation of structures, and the normal direction compensation method is more efficient. This paper provides an important reference for the improvement of manufacturing accuracy and process optimization of the new generation of autobody closure panels with dissimilar materials.

Key words: dissimilar material hemming-structure, curing deformation, multi-physics fields, geometric compensation, surface reconstruction

中图分类号:

U463

李建军, 朱文峰, 孙海涛, 李元辉, 王顺超. 异质滚合结构固化变形预测及曲面重构预补偿方法[J]. 上海交通大学学报, 2022, 56(7): 965-976.

LI Jianjun, ZHU Wenfeng, SUN Haitao, LI Yuanhui, WANG Shunchao. Method of Curing Deformation Prediction and Surface Reconstruction Compensation for Roller-Hemming Structures with Dissimilar Materials[J]. Journal of Shanghai Jiao Tong University, 2022, 56(7): 965-976.

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参数	取值	参数	取值
A/min^-1	5.89×10¹⁰	b₂/℃^-1	0.01592
E_a/(KJ·mol^-1)	91.62	c₁/℃^-1	0.0224
m'	0.61	s₀/(℃·MPa^-1)	3.34
n'	1.72	q_gel	0.45
V₀/(cm³·g^-1)	0.8251	T_g/℃	88~91
k₁/℃^-1	1.5×10^-4	G_final/MPa	58.3
k₂/℃^-1	2.7×10^-4	K_adh/[W·(m·℃)^-1]	0.2
b₁/MPa	428.1	—	—

参数	取值/MPa	参数	取值/h
G_∞	100.4	τ₀	—
G₁	28.3	τ₁	2.1×10³
G₂	29.3	τ₂	2.4×10¹⁰
G₃	37.9	τ₃	5.2×10³
G₄	28.4	τ₄	7.2×10³
G₅	27.9	τ₅	2.4×10³
G₆	46.7	τ₆	2.5×10⁶
G₇	89.3	τ₇	1.8×10⁴
G₈	79.4	τ₈	2.2×10³
G₉	94.6	τ₉	4.3×10⁸
G₁₀	66.4	τ₁₀	5.6×10⁹

材料名称	c/[J·(Kg·K)^-1]	α_V/K^-1	G/GPa	K/GPa	k_i/[W·(m·K)^-1]
AA6016-T4	896	23.2×10⁶	26.5	57.5	167
DC04	509	12.5×10⁶	80.7	175	50.2