复杂钣金零件工序形状设计技术研析.pdf

摘 要 复杂钣金零件的展开毛坯与中间工序形状的设计与计算是冲压工艺设计中的重 要环节。随着制造业及高新技术的发展，钣金零件的形状越来越复杂，质量和精度 要求越来越高，传统的手工设计计算方法已难以满足复杂钣金零件工序形状的快速 和精确求解要求。以有限元理论为基础的板料成形数值模拟技术的出现，为解决上 述问题提供了有效手段。 本文主要研究以冲压成形模拟软件FASTAMP 为求解器，基于UGNX 平台构建 复杂钣金零件的工序形状设计系统的技术。首先，介绍了 FASTAMP 的原理和应用 范围，接着分析了 FASTAMP 求解器的输入和输出数据格式。在此基础上，以复杂 钣金零件的多工序形状为目标，对钣金零件多工序展开数值模拟关键技术进行了研 究和探索，分析了钣金零件有限元模型的建立和网格划分的基本原则、工序间变形 历史信息的传递、多工序划分的合理性等问题，为实现FASTAMP 和基于UGNX 的 工序形状设计系统的集成奠定了基础。另外，由于求解器生成的是展开毛坯的轮廓 曲线，为获得中间工序形状，如何从轮廓曲线生成曲面成为一个需要解决的关键问 题。为此，对基于曲线轮廓的曲面重构方法进行了研究和实现。 根据以上的研究，在UGNX 平台下，实现了复杂钣金零件多工序形状设计系统 的开发。利用该系统可快速精确地获得复杂钣金零件的中间工序形状，为冲压工艺 设计提供了有效的设计手段。 关键词：复杂钣金零件、冲压成形模拟、工序形状设计、曲面重构 I Abstract The design of blank shape and process shape for sheet metal parts is an important works of designing stamping process. With the rapid development of manufacturing industrial and high technology, the shape of sheet metal parts is more and more complex, and the quality precision requirement of sheet metal parts is higher and higher. Traditional hand-made methods of blank and process design are not available to many complex sheet metal parts. However, the FEM-based simulation for stamping process can help overcome the problems. With FASTAMP, which is a fast stamping simulation FEM software, as the solver, a UGNX-based system of designing the multiple-step process shapes of complex sheet metal parts is developed. Firstly, the principle and application of FASTAMP are introduced. Secondly, the input and output data of FASTAMP are analyzed. Based on these, the key technologies of multiple-step process shape simulation of complex sheet metal parts are studied, which include the building of FEM model, the