CN109702931B - Design Method of Die Profile for Accurate Thermoforming of Large Component with Computer Aided - Google Patents
Design Method of Die Profile for Accurate Thermoforming of Large Component with Computer AidedDownload PDFInfo
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- CN109702931B CN109702931BCN201910089528.3ACN201910089528ACN109702931BCN 109702931 BCN109702931 BCN 109702931BCN 201910089528 ACN201910089528 ACN 201910089528ACN 109702931 BCN109702931 BCN 109702931B
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Abstract
Translated fromChinese
Description
Technical Field
The invention relates to the technical field of metal plate and composite material hot forming manufacturing, in particular to a method for designing a mold surface of a mold for computer-aided large-scale member accurate hot forming.
Background
Referring to fig. 1 and 2, the thermoforming process of the metal member and the composite material member requires a corresponding forming mold surface to give the shape to the metal member and the composite material member, and the dimensional accuracy of the forming mold surface is an important guarantee for the dimensional accuracy of the member shape. The existing mold surface design is mostly finished through computer aided design, and the existing design method mostly directly takes the target mold surface of the component at room temperature as the mold surface of the forming mold, and ignores the influence of the thermal expansion deformation of the mold surface of the forming mold at the component hot forming temperature on the dimensional precision of the component. The molded surface of the member during hot forming is ensured by the molded surface of the mold after hot deformation at the hot forming temperature, the molded surface of the mold at the hot forming temperature is larger than the hot deformation at room temperature along with the increase of the size of the member, particularly for large members such as airplane skins and airplane wings, the length of the large members can reach dozens of meters, the deformation amount of a corresponding mold between the hot forming temperature and the normal temperature is considerable, and the influence on the size precision of the member is not negligible, so a mold molded surface design method considering the hot deformation of the mold is needed in the prior art to solve the problem.
The chinese patent 201810739174.8 discloses a springback compensation method for thermoforming, which comprises three steps, respectively:
step S100: establishing a finite element simulation model, and obtaining a creep component after creep aging forming of the component;
step S200: making the component outer profile subjected to iterative compensation rebound each time be Pi (i is 0, 1, 2, 3.. said., 0 is a rebound profile obtained by first simulation), deleting the mold profile Mi (i is 0, 1, 2, 3.. said., 0 is a mold profile input in first simulation, namely a target profile of the component), calculating the vertical distance delta Zij from each node on the rebound outer profile Pi subjected to rebounding of the creep component to each node on the target profile Pgoal, wherein delta Zij represents the vertical distance from each node on the rebound outer profile Pi subjected to rebounding of the creep component to the target profile Pgoal, taking the vertical distance maximum max (delta Z) of the vertical distance delta Zij in each node, judging whether the vertical distance maximum max (delta Z) is not more than the engineering error, and if the judgment result is yes, taking the current mold profile Mi corresponding to the rebound outer profile Pi of the component as the rebound compensation mold and performing step S300, if the judgment result is no, constructing a mold surface for the (i + 1) th simulation, and repeating the steps S100-200 until the judgment is yes;
step S300: and establishing a component creep aging forming die according to the profile of the rebound compensation die, performing die cooling finite element simulation on the component creep aging forming die to obtain the profile of the rebound thermal expansion die, setting the initial temperature as the forming temperature of the component in the step of creep aging forming of the component in the die cooling finite element simulation, and inputting the cooling curve of the component in the step of creep aging forming.
However, the method disclosed in patent 201810739174.8 has the following disadvantages: one is that the number of iterations of steps S100 and S200 is large, and the other is that after step S300, the subsequent die repair amount of the solid die is large, which increases the workload. In particular, for the first disadvantage mentioned above, as described in the example of patent 201810739174.8, it takes 3 iterations to obtain a mould profile that meets the tolerance requirements for an aluminium alloy member having overall dimensions 435.0mm long × 293.7mm wide × 17mm high. Due to the fact that the iterative calculation workload is large and time is consumed, and for large components with the length size of at least more than 10 meters, such as aircraft skins and aircraft wings, the computer needs to wait for one day or even longer time every time the iterative calculation is carried out, a large amount of valuable time of a mold designer is consumed, the iterative calculation of component rebound is considered, the number of times of the iterative calculation is generally more than 4-6 times, and the working efficiency is seriously influenced.
Therefore, there is still a need in the art for a method for designing a mold surface of a large-sized member for precision thermoforming, which has a small solid modification number and can reduce the amount of iterative computations, so as to reduce the waiting time of mold designers and improve the working efficiency.
Disclosure of Invention
The invention aims to provide a method for designing a mold surface of a computer-aided large-scale component precise hot forming mold so as to solve the problems in the background technology.
A method for designing a mold surface of a computer-aided large-scale component precise hot forming mold comprises the following steps:
1) with the target profile S of the component0Is the original molded surface B of the mold0The two are matched in a concave-convex way,and according to B0Designing a corresponding three-dimensional mold model, and setting the molded surface as B in finite element analysis software0The mold is cooled from high temperature to room temperature to obtain a cooled mold, and the molded surface B of the cooled mold is extracted1Wherein the high temperature value is equal to the temperature value of the thermal forming and heat preservation stage corresponding to the component;
2) with the profile B of the cooled mold1Generating a three-dimensional mold model as an initial molded surface, establishing a thermal forming simulation model on the basis of the three-dimensional mold model and a member raw material, and setting the molded surface as B1On the basis of the die, the first hot forming simulation is carried out on the component raw material to obtain the initial hot forming molded surface S of the component1Calculating the initial hot-forming profile S of the component1Each point and component target profile S0Initial forming error u of each point1Judging the initial forming error u of each point1If the two are all less than or equal to the range epsilon allowed by engineering error, the molded surface S is initially hot-formed by the member1Corresponding mold surface B1Taking the obtained target molded surface of the mold as a final target molded surface, and if not, entering the step 3;
3) in finite element software, according to SiAnd S0To the size of the error, to the hot forming profile S of the componentiCorresponding mold surface BiPerforming the i-th rebound compensation calculation to obtain the mould profile B after the rebound compensationi+1Proceeding to step 4 as the mold surface of the i +1 th thermoforming, wherein i is (1, 2, 3 … … n);
4) according to the mould profile Bi+1Generating a three-dimensional die model, establishing a thermal forming simulation model on the basis of the three-dimensional die model and the component raw material, and setting the molded surface as Bi+1On the basis of the die, the thermal forming simulation is carried out on the component raw material to obtain the thermal forming molded surface S of the componenti+1Calculating the hot forming profile S of the componenti+1Each point and component target profile S0Forming error u of each pointi+1Determining the forming error u of each pointi+1If the two are all less than or equal to the range epsilon allowed by engineering error, the profile S is hot-formed by the componenti+1To what is providedCorresponding mould surface Bi+1If not, the process returns to step 3 by setting i to i + 1.
The generation of the three-dimensional model is completed in three-dimensional modeling software such as CATIA, ProE or Solid works and the like.
The cooling simulation and the thermoforming simulation are completed in finite element analysis software such as ABAQUS, ANSYS or MSC and the like.
The component material can be alloy or fiber resin composite material, and the hot forming can be creep age forming of the alloy in an autoclave or hot press solidification forming of the fiber resin composite material in the autoclave correspondingly.
The material of the mould can be carbon steel or other metal structural materials or non-metal structural materials.
The invention has at least the following beneficial effects:
the invention relates to a method for designing a computer-aided large-scale component accurate hot forming die, which uses a die cooling molded surface B1As an initial value of the iterative calculation, the mold cooling profile B1Original molded surface B of the mold0(i.e., the component target profile S0Concave-convex mating surface of) is closer to the target mold surface than to the target mold surface S directly from the member0As a mode of iterative computation of an initial value, the method can reduce the iteration times by about 50 percent, greatly improve the solving efficiency, save the precious time of a mold designer, and particularly has more obvious advantage for large-scale components.
The invention is based on the basic idea of mathematical optimization, and one of the best methods is to provide an iteration initial value closer to the optimal solution in order to reduce the iteration times, and the reasonable iteration initial value is very effective to the iteration efficiency. In the method of the invention, the finite element cooling is solved to the mould surface B1The process of (1) is a process of providing a reasonable iteration initial value, and the subsequent forming springback iteration compensation process is a optimizing process. The invention firstly determines an initial value which is closer to the optimal solution before the iterative process of component forming and springback compensation, and then iterates the initial value, thereby achieving the purpose of reducing the iteration times.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of a thermoforming process of a component in a mold;
FIG. 1 includes FIGS. 1a and 1b, wherein FIG. 1a is a schematic view of a component before thermoforming and FIG. 1b is a schematic view of a component during thermoforming;
FIG. 2 is a schematic thermal deformation of a mold;
FIG. 2 includes FIGS. 2a and 2b, wherein FIG. 2a is the mold before hot deformation and FIG. 2b is the mold after hot deformation;
FIG. 3 is a logic block diagram of the steps of a method for designing a mold surface for computer-aided precise hot forming of a large member according to a preferred embodiment of the present invention.
Detailed Description
Embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways, which are defined and covered by the claims.
The method for designing the mold surface of the computer-aided precise hot forming large-scale component with reference to fig. 3 comprises the following steps:
1) with the target profile S of the component0Is the original molded surface B of the mold0(i.e., the design value of the mold surface), the two are matched in a concave-convex mode and are according to B0Designing a corresponding three-dimensional mold model, wherein the molded surface is B in finite element software0The mold is cooled from high temperature to room temperature to obtain a cooled mold, and the molded surface B of the cooled mold is extracted1(i.e., the mold surface at room temperature), wherein the high temperature value is equal to the temperature value of the thermal forming and heat preservation stage corresponding to the component;
2) with the profile B of the cooled mold1Generating a three-dimensional mold model as an initial molded surface, establishing a thermal forming simulation model on the basis of the three-dimensional mold model and a member raw material, and setting the molded surface as B1On the basis of the die, the first hot forming simulation is carried out on the component raw material to obtain the initial hot forming molded surface S of the component1Calculating the initial hot-forming profile S of the component1Each point and component target profile S0Initial forming error u of each point1Judging the initial forming error u of each point1If the two are all less than or equal to the range epsilon allowed by engineering error, the molded surface S is initially hot-formed by the member1Corresponding mold surface B1Taking the obtained target molded surface of the mold as a final target molded surface, and if not, entering the step 3;
3) in finite element software, according to SiAnd S0To the size of the error, to the hot forming profile S of the componentiCorresponding mold surface BiPerforming ith rebound compensation calculation (namely, according to the rebound deformation of the pressure-relief member, the molded surface B of the mold is subjected toiRepaired) to obtain Bi+1Proceeding to step 4 as the mold surface of the i +1 th thermoforming, wherein i is (1, 2, 3 … … n);
4) according to the mould profile Bi+1Generating a three-dimensional die model, establishing a thermal forming simulation model on the basis of the three-dimensional die model and the component raw material, and setting the molded surface as Bi+1On the basis of the die, the thermal forming simulation is carried out on the component raw material to obtain the thermal forming molded surface S of the componenti+1Calculating the hot forming profile S of the componenti+1With the target profile S of the component0Forming error u of each pointi+1Determining the forming error u of each pointi+1If the two are all less than or equal to the range epsilon allowed by engineering error, the profile S is hot-formed by the componenti+1Corresponding mold surface Bi+1If not, the process returns to step 3 by setting i to i + 1.
The specific implementation process of the invention is roughly as follows:
target profile S of component in the design of component product0Then, a mold original profile B which is completely matched with the original profile B in a concave-convex mode (the curvature and the size of the profile are equal) is designed0。
In the finite element software, the original molded surface B of the mold is processed0Setting the corresponding mold profile at high temperature (such as 180 ℃ or 200 ℃) for forming heat preservation, and simulating the mold cooling profile B when the mold is cooled to room temperature by utilizing finite element analysis software1The case (1).
Simulating the cooling molded surface B of the mold by a computer1The raw material of the upper member, such as a flat plate-like aluminum alloy plate or a prepreg of a carbon fiber resin composite material, is put on and creep age-forming is performed on the aluminum plate, or hot press curing is performed on the carbon fiber resin composite material. The initially hot formed profile S of the component of the first component obtained at this point1The dimensions of the component generally must not conform to the target profile S of the design0Error requirement of (1), will S1And S0And (6) data comparison is carried out.
According to the formula S1And S0Carrying out first computer simulation on the deviation condition after data comparison and comparison (namely the component springback compensation process) to obtain a mold surface B of the mold after mold trimming2Then, a second time of simulating the creep forming process of the component is carried out to obtain a component hot forming profile S of the second component2Will S2And S0And performing data comparison, and repeating the steps until qualified components are produced. I.e. the component S produced after the final n times of die repair and after the (n + 1) th component simulation forming processn+1Size of (D) and S0If the error of the comparison is within the allowable range, the iteration is stopped, and the corresponding die Bn+1Namely the qualified die designed by the computer.
Since the specific cooling simulation, the thermal forming simulation (including creep aging forming and hot press curing forming) and the calculation method for the component springback compensation are all the prior art, the detailed description is not provided in the present invention.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. A method for designing a mold surface of a computer-aided large-scale component precise hot forming mold is characterized by comprising the following steps:
1) taking the target component profile S0 as the original mould profile B0, matching the target component profile S0 with the original mould profile B0 in a concave-convex manner, designing a corresponding three-dimensional mould model according to B0, performing cooling simulation on the mould with the profile B0 in finite element analysis software from high temperature to room temperature to obtain a cooled mould, and extracting the profile B1 of the cooled mould, wherein the high-temperature value is equal to the temperature value of the thermal forming and heat preservation stage corresponding to the component;
2) generating a three-dimensional mold model by taking the molded surface B1 of the cooled mold as an initial molded surface, establishing a thermal forming simulation model on the basis of the three-dimensional mold model and a component raw material, performing a first thermal forming simulation on the component raw material on the basis of the mold with the molded surface B1 to obtain an initial thermal forming molded surface S1 of the component, calculating initial forming errors u1 of each point of the initial thermal forming molded surface S1 and each point of a target molded surface S0 of the component, judging whether the initial forming errors u1 of each point are smaller than or equal to an engineering error allowable range epsilon, if so, taking the mold molded surface B1 corresponding to the initial thermal forming molded surface S1 of the component as a finally-obtained target molded surface of the mold, and if not, entering the step 3;
3) in finite element software, according to the error magnitude between Si and S0, performing ith rebound compensation on the die profile Bi corresponding to the component hot forming profile Si to obtain a die profile Bi +1, and performing step 4 as the die profile of the ith +1 hot forming, wherein i is (1, 2, 3 … … n);
4) the method comprises the steps of generating a three-dimensional die model according to a die profile Bi +1, establishing a thermal forming simulation model on the basis of the three-dimensional die model and a component raw material, performing thermal forming simulation on the component raw material on the basis of a die with a profile Bi +1 to obtain a component thermal forming profile Si +1, calculating forming errors ui +1 of each point of the component thermal forming profile Si +1 and each point of a component target profile S0, judging whether the forming errors ui +1 of each point are smaller than or equal to an engineering error allowable range epsilon, if so, taking the die profile Bi +1 corresponding to the component thermal forming profile Si +1 as a finally-obtained die target profile, and if not, making i +1, and returning to the step 3.
2. The method of claim 1, wherein the generation of the three-dimensional model is performed in CATIA, ProE or Solid works three-dimensional modeling software.
3. The method of claim 1, wherein the cooling simulation and the thermoforming simulation are performed in ABAQUS, ANSYS or MSC finite element analysis software.
4. The method for designing the mold surface of the computer-aided large member for the precise hot forming of the large member according to any one of claims 1 to 3, wherein the member is made of an alloy or a fiber resin composite material.
5. The method for designing the mold surface for computer-aided precise hot forming of the large component according to claim 4, wherein the hot forming is creep age forming of aluminum alloy in an autoclave or hot press curing forming of fiber resin composite material in the autoclave.
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| CN111873481B (en)* | 2020-07-01 | 2022-01-07 | 西北工业大学 | Compensation method for composite material forming resilience and die with adjustable forming surface |
| CN112733291B (en)* | 2020-12-31 | 2022-04-12 | 中南大学 | A precise compensation method for mold surface with complex curvature surface |
| CN113306051B (en)* | 2021-05-26 | 2022-02-15 | 南京航空航天大学 | Method for determining molded surface of forming die for curing composite material member |
| CN119692085B (en)* | 2024-10-18 | 2025-10-03 | 河源市华益盛模具有限公司 | Iterative optimization method, equipment and medium for molding surface of automobile part mold |
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| EP2559533B1 (en)* | 2008-09-26 | 2020-04-15 | United Technologies Corporation | Casting |
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