解析LS-DYNA的电子元件冲压成形仿真研究.docVIP

基于LS-DYNA的电子元件冲压成形仿真研究 孙启新，杨进 （淮海工学院 机械工程学院，江苏 连云港 222005） 摘要：针对电子元件结构尺寸较小，采用传统方法设计其成形模具效率低且很难保证质量的特点，运用LS-DYNA接触碰撞算法，建立了工件、凸凹模的冲压成形有限元模型，定义成形条件。在分析过程中通过创建接触界面来实现凸凹模与工件之间力和运动的传递。分析得到了工件应力应变分布图和成形性能图。结果表明工件成形性能良好；而且采用接触碰撞算法可根据节点的时间-位移图来判断工件成形质量，并通过调整分析输入参数来获得最佳成形条件：凸凹模间隙和冲压速度。将仿真分析结果应用到模具设计和冲压工艺参数的拟订定中，实际生产表明仿真分析数据合理可靠。 关键词: 接触碰撞算法；冲压成形；有限元；仿真 中图分类号: 文献标识码: A Research of stamping forming simulation for electronic component based on LS-DYNA SUN Qi-xin，Yang Jin (College of Mechanical Engineering, Huaihai Institute of Technology, Lianyungang， Jiangsu 222005, China) Abstract： In order to improve stamping forming efficiency and quality of the electronic component, the finite element models of workpiece and punch-matrix were established according to contact-impact algorithm along with contact pair. Then simulation analysis was carried based on LS-DYNA. During the analysis, the force and motion transmission between punch-matrix and workpiece were realized through the contact-impact interface defined. Strain-stress figure and forming limit diagram were obtained. Analysis results indicated that the forming property of workpiece was fine. In addition, this method could realize the checkout of stamping forming quality. And the optimal forming factors, clearance and velocity of punch-matrix, were got by the adjusting of the analysis input parameters. The obtained results were well in agreement with practical product data. Key words: contact-impact algorithm; stamping forming; finite element; simulation analysis 1引言 在电子工业领域，电子元件为了后续工序的组装，需将其触角弯曲成所需要的形状。由于此类元件导电部位的主要材料是铜、铝合金等，这些材料较软、抗拉强度低，加上零件尺寸较小，所以在模具设计和冲压工艺参数的选择等方面与普通的冲压件有所不同。特别是在发生弹性压缩或拉伸时，金属的电阻率一般会发生变化，所以对其成形精度要求很高。为保证成形质量，在设计其模具时需进行大量的计算和实验，造成设计进度的缓慢和花费大量的实验经费。 本文以某品牌汽车刹车系统中传感器上的电阻（其结构如图1所示）为例，采用ANSYS/LS-DYNA对其弯曲成形过程进行有限元仿真分析，以获得冲压生产过程中所需工艺参数，并为模具结构设计及其工作尺寸的确定提供参考依据。这样可将试模从生产车间移到计算机上，而且将试模穿插在模具设计过程中，大大缩减了设计周期和生产成本。在实际上生产中取得了不错的效果。 2 接触碰撞有限元算法 冲压成形过程是一个大变形的非线性力学过程，其有限元仿真分析以增量法为主，经有限元离散化之后建立板料