无铆钉铆接的工艺分析-technological analysis of rivet - free riveting.docxVIP

摘要 摘要 I I 无铆钉铆接的工艺研究 摘要 随着家电及汽车等机械行业的发展和竞争的加剧，这些领域越来越追求加工制造的 自动化及高效、快捷性，家电和汽车等机械产品中有不少板料连接件，而无铆钉铆接很 适合实现自动化，以提高制造的高效、快捷性，降低生产成本，降低劳动强度。而且无 铆钉铆接疲劳强度比点焊高，对于汽车等处于振动工况的机械产品是一个必备的优点。 要提高汽车的经济性，可以采用铝镁合金等轻型材料，常用的点焊难于连接，而无铆钉 铆接能进行较好连接。 本文首先利用 DEFORM- 2D 有限元软件建立无铆钉铆接有限元模型，对铆接过程进行 有限元模拟，分析铆接成形过程中的五个阶段。对模拟过程的应力应变进行了分析，结 果表明应力应变主要集中在凸模下面板料及上板料嵌入下板料的镶嵌部分。研究了铆接 成形过程中的载荷- 行程变化趋势。 其次对不同厚度板料的组合进行模拟，对模拟结果分析，得到影响铆接接头性能主 要工艺参数：凸模和凹模形状及尺寸，被铆接的上、下板料的厚度，上、下板料的材料， 被铆接板料的机械性能等；并提出制定工艺时的注意事项。 最后分析了凹模深度、凹模环形凹槽深度、凸模圆角大小、上下层板料放置顺序（包 括厚度不同和材料不同）对无铆钉铆接接头性能的影响。提出在此情况下凸模和凹模形 状的设计原则，为实际设计模具提供了参考。利用多种组合的有限元模拟结果和实验结 果，对上、下板料厚度改变情况下铆接接头性能缺陷进行分析和提出解决方案，对无铆 钉铆接工艺的制定具有一定的指导意义。 关键词：有限元模拟，无铆钉铆接，DEFORM Abstract Abstract II II STUDY OF CLINCHING TECHNOLOGY ABSTRACT With the development and intense competition of machinery industry, such as household appliances and automotive industries.It demands to manufacture more automationally and efficiently.There are a lot of metal sheets connectors in the household electrical appliances, vehicles, and other machinery products, clinching is very suitable to achieve efficient manufacture, lower production costs, and less labor intensity. There is higher fatigue strength of clinching than the spot welding.It is a definite advantage to have the high fatigue shength for the automotive and other mechanical products that serve in the vibration condition. To improve the economics, lightweight materials such as aluminium-magnesium alloy are used in automotive industry, and the common spot welding is difficult to connect them, clinching is the better choice. Firstly, finite element model of clinching is established on DEFORM-2D software. The finite element simulation of the clinching process is carried out, and five stages of forming process of the riveting are analyzed. Distribution of stress and strain during forming process are analyzed.The results show that stress and strain are mainly concentrated on the sheet under the punch and the mosaic part that the upper sheet embed