整车焊点失效预测的研究及应用
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摘要
通过在CAE模型中对焊点添加失效判据,解决了汽车碰撞有限元模拟中难以准确预测焊点失效的问题。基于焊点力学性能试验获取的焊点失效参数建立焊点失效判据;通过多焊点部件的仿真与试验对比,验证了焊点失效判据的有效性。结果表明,添加焊点失效判据能反映真实的焊点受力和失效情况。在整车碰撞模型中进行焊点失效预测,并通过与实车碰撞结果的对比,表明该方法能准确预测出实车碰撞中的焊点失效情况,对整车碰撞安全设计具有指导意义。
By adding failure criterion on welding spots in CAE model, the difficulty in accurately predicting welding spot failure during vehicle crash simulation with finite element analysis is overcome. Welding spot failure criteria are set up based on welding spot failure parameters obtained from the mechanical performance test of welding spots, and the effectiveness of welding spot failure criteria is verified by comparing the results of simulation and test on multi-welding-spot components. The results show that adding failure criterion on welding spots can truly reflect the loading and failure conditions of welding spots. Then the prediction on welding spot failure is conducted on vehicle crash model and is compared with the results of real-vehicle crash test. The outcomes indicate that the method adopted can accurately predict the welding spot failure situation in real vehicle crash, having guiding significance for the crash safety design of vehicle.
By adding failure criterion on welding spots in CAE model, the difficulty in accurately predicting welding spot failure during vehicle crash simulation with finite element analysis is overcome. Welding spot failure criteria are set up based on welding spot failure parameters obtained from the mechanical performance test of welding spots, and the effectiveness of welding spot failure criteria is verified by comparing the results of simulation and test on multi-welding-spot components. The results show that adding failure criterion on welding spots can truly reflect the loading and failure conditions of welding spots. Then the prediction on welding spot failure is conducted on vehicle crash model and is compared with the results of real-vehicle crash test. The outcomes indicate that the method adopted can accurately predict the welding spot failure situation in real vehicle crash, having guiding significance for the crash safety design of vehicle.
引文
[1] SONG J H, HUH H. Failure characterization of spot welds under combined axial-shear loading conditions[J]. International Journal of Mechanical Sciences,2011,53(7):513-525.
[2] 何文,张维刚,钟志华.汽车碰撞仿真研究中点焊连接关系的有限元模拟[J].机械工程学报,2005,41(9):73-77.
[3] KUMAGAI K, HAYASHI S, OHNO T. Rupture modeling of spot welds under dynamic loading for car crash FE analysis[C]. 6th LS-DYNA Anwenderforum,2007:17-24.
[4] 王赢,常光宝,倪小波.汽车碰撞分析中焊点模拟的研究[J].科技视界,2015(18):90-91.
[5] 高卫民,王宏雁,徐敦舸.碰撞模拟过程中焊点的影响[J].同济大学学报(自然科学版),2001,29(7):870-872.
[6] 张涛,李光耀,陈涛.基于耐撞性的前纵梁焊点模拟及其优化设计[J].汽车工程,2010,32(6):524-529.
[7] 项玉江,范子杰.帽型薄壁管件准静态压溃模拟计算中焊点的处理方法[J].汽车工程,2004,26(6):750-754.
[8] 施欲亮,朱平,沈利冰,等.基于汽车碰撞仿真的点焊连接关系有限元模拟方法[J].机械工程学报,2007,43(7):226-230.
[9] 张涛,李光耀,陈涛.基于耐撞性的前纵梁焊点模拟及其优化设计[J].汽车工程,2010,32(6):524-529.
[10] 吴鑫.车身焊点材料动态本构研究[D].宁波:宁波大学,2014.
[11] 蒋小晴,杨济匡,肖志,等.前纵梁碰撞模拟中的焊点建模方法比较[J].汽车安全与节能学报,2010,1(4):327-331.
[12] 谢斌,成艾国,陈涛,等.基于汽车碰撞仿真的实体单元焊点模拟方法研究[J].中国机械工程,2011(10):1226-1231.
[13] MALCOLM S, NUTWELL E. Spotweld failure prediction using solid element assemblies[C]. 6th European LS-DYNA Users'Conference,2011:47-56.
[2] 何文,张维刚,钟志华.汽车碰撞仿真研究中点焊连接关系的有限元模拟[J].机械工程学报,2005,41(9):73-77.
[3] KUMAGAI K, HAYASHI S, OHNO T. Rupture modeling of spot welds under dynamic loading for car crash FE analysis[C]. 6th LS-DYNA Anwenderforum,2007:17-24.
[4] 王赢,常光宝,倪小波.汽车碰撞分析中焊点模拟的研究[J].科技视界,2015(18):90-91.
[5] 高卫民,王宏雁,徐敦舸.碰撞模拟过程中焊点的影响[J].同济大学学报(自然科学版),2001,29(7):870-872.
[6] 张涛,李光耀,陈涛.基于耐撞性的前纵梁焊点模拟及其优化设计[J].汽车工程,2010,32(6):524-529.
[7] 项玉江,范子杰.帽型薄壁管件准静态压溃模拟计算中焊点的处理方法[J].汽车工程,2004,26(6):750-754.
[8] 施欲亮,朱平,沈利冰,等.基于汽车碰撞仿真的点焊连接关系有限元模拟方法[J].机械工程学报,2007,43(7):226-230.
[9] 张涛,李光耀,陈涛.基于耐撞性的前纵梁焊点模拟及其优化设计[J].汽车工程,2010,32(6):524-529.
[10] 吴鑫.车身焊点材料动态本构研究[D].宁波:宁波大学,2014.
[11] 蒋小晴,杨济匡,肖志,等.前纵梁碰撞模拟中的焊点建模方法比较[J].汽车安全与节能学报,2010,1(4):327-331.
[12] 谢斌,成艾国,陈涛,等.基于汽车碰撞仿真的实体单元焊点模拟方法研究[J].中国机械工程,2011(10):1226-1231.
[13] MALCOLM S, NUTWELL E. Spotweld failure prediction using solid element assemblies[C]. 6th European LS-DYNA Users'Conference,2011:47-56.