基于有限元模拟的自冲铆接工艺参数优化

Parameter Optimization of Self-Piercing Riveting Process Based on Numerical Simulation

对2 mm+2 mm搭接的5052 H32铝合金板自冲铆接工艺进行数值模拟,采用L9(3~4)正交表选取铆钉长度、铆钉直径及模具凹下面积3个因素的3个水平,以接头剪切强度最大为目标,首先模拟铆接接头形成的下压过程,并将模拟获得的接头形貌与试验结果对比一致后,再模拟三维剪切拉伸过程获得接头的剪切力学性能,通过方差分析得出最佳工艺参数为铆钉长度6.5 mm,铆钉直径5.14 mm,模具凹部面积5.12 mm^2。同时,将各尺寸因素对接头横截面形貌、下压过程及剪切拉伸过程的力-位移曲线、接头的等效应力和塑性应变的影响进行分析。对自冲铆接工艺过程建立了完善的有限元模型,该模拟方法可作为自冲铆接工艺设计及其工艺参数优化的依据。

In this study,the numerical simulation of the self-piercing process of 5052-H32 aluminum alloy plate with the 2 mm+2 mm lap joints were carried out. The rivet length,rivet diameter and the die concave area were selected from a L9(3^4) orthogonal array. The three-dimensional shear stretching process was simulated and the shear stresses of the joints were obtained. The optimum parameters were determined to be a rivet length of 6.5 mm,rivet diameter of 5.14 mm,the die concave area of 5.12 mm^2 by applying the variance analysis. The influences of the size factors on the cross-sectional topography of the joint,the forcedisplacement curves for both the undercutting process and the tensile-shear process,and the equivalent stress and the plastic strain of the joint were analyzed. In this study,the complete FEM model for the self-piercing riveting process was established and the simulation method can be used for the design of SPR process and the optimization of processing parameters.