无铆钉铆接的工艺研究

华东交通大学硕士学位论文无铆钉铆接的工艺研究姓名：陈兴茂申请学位级别：硕士专业：机械制造及其自动化指导教师：黄志超20080418IDEFORM-2D-DEFORMAbstractIISTUDYOFCLINCHINGTECHNOLOGYABSTRACTWiththedevelopmentandintensecompetitionofmachineryindustry,suchashouseholdappliancesandautomotiveindustries.Itdemandstomanufacturemoreautomationallyandefficiently.Therearealotofmetalsheetsconnectorsinthehouseholdelectricalappliances,vehicles,andothermachineryproducts,clinchingisverysuitabletoachieveefficientmanufacture,lowerproductioncosts,andlesslaborintensity.Thereishigherfatiguestrengthofclinchingthanthespotwelding.Itisadefiniteadvantagetohavethehighfatigueshengthfortheautomotiveandothermechanicalproductsthatserveinthevibrationcondition.Toimprovetheeconomics,lightweightmaterialssuchasaluminium-magnesiumalloyareusedinautomotiveindustry,andthecommonspotweldingisdifficulttoconnectthem,clinchingisthebetterchoice.Firstly,finiteelementmodelofclinchingisestablishedonDEFORM-2Dsoftware.Thefiniteelementsimulationoftheclinchingprocessiscarriedout,andfivestagesofformingprocessoftherivetingareanalyzed.Distributionofstressandstrainduringformingprocessareanalyzed.Theresultsshowthatstressandstrainaremainlyconcentratedonthesheetunderthepunchandthemosaicpartthattheuppersheetembeddedintothebottomsheet.Thispaperhasstudiedtrendencyoftheload-strokecurve.Secondly,thespecimenswithdifferentthicknesssheets(uppersheetandlowersheet)aresimulated,andthesimulationresultsareanalyzed.Themaintechnologyparameterswhichinfluencetheperformanceofrivetedjointareobtained,theseparametersaretheshapeandsizeofpunchandconcavemold,thethicknessoftheuppersheetandbottomsheetthematerialofthesheetsthemechanicalpropertiesoftherivetedmetalsheetandsoon.Andtheattentionmattersofthetechnologyareproposed.Finally,theeffectofthedepthoftheconcavemold,thegroovedepthoftheringintheconcavemold,punchfilletsizeandlayingorderofthematalsheets(differentthicknessanddifferentmaterial)thatinfluencejointperformanceofclinchingareanalyzed.Moreover,theprinciplesofdesigningpunchandconcavemoldshapeareproposed.Thiscanprovidesomereferencesformolddesign.Makinguseofthefiniteelementsimulationresultsandtheexperimentresultsofthemanykindsofcombinations,theperformanceflawsandthesolutionsofclinchingareforecasted.Thiscanprovidecertainreferencestothepracticalapplicationofclinching.KeyWords:numericalsimulation,clinching,DEFORM____________________________________________________________11.1103.8856CO4.57[1,33]TOX,,[2][4]DEFORM21.2TOX1.2.1TOXTOXTOXTOXTOXRUDORFEBERLE(a)(b)(c)(d)1-1[36]Fig.1-1anIllustrationofClinching1.2.2:,3,(),,,,TOX70%,,,,TOX[3]TOXTOX3TOX[3]:1()23456789101112131441-1[42]TOXTOXTOX40%-70%[3]1-2[5]0.3mm8mm234()51270%25008mm11mm6mm242/206020401.2.3TOXTOXTOXTOXA62002POLOTOXPOLOTOXPOLO++79TOXTouranA-MPVPassatB6,Golf-5AudiA4AudiC6AudiA6307BMW5TOX[3]TOX()6TOXZiehl-AbeggAppleBMWBosch-Simens[5]TOXTOX[6]TOX[7]TOX[8](a)POLO[3]bPOLO[3]1-2Fig.1-2ApplicationofClinchinginAutomobileBodyManufacture1.3X”,[3]()Tox40%-70%[12][5]TOX70%TOX[9]TOXTOX[6]TOXTOXTOX7TOX[9],,,,,[10],,.:,;[12],1.5[11],,,,[13]TOXTOXTOX90%[14],TOX(),,,,,[15]TOXTOXTOX[8]TOX12[9]TOXTOXTOX[16]TOXTOXTOX,TOX[17]8,,,[18,19],[19]J.P.Varis[20]M.Carboni50%[21]JuhaVaris[22]JuhaVaris[23]A.A.dePaulaa[24]R.F.Pedreschia[25]9R.Lennon[26]R.F.Pedreschi[27]K.Taube[28]1.41DEFORMCAD--234102.12-1[35]2-1(a)232-1(b)4mm2-1(c)(a)(b)(c)2-1Fig.2-1ThreeFormsofClinching,2-2a2-2b11ab2-2.Fig.2-2ProfilesofClinching2.2abcde1.2.3.4.2-3.Fig.ProcessofClinching12-3a22-3b,,12,,,,,,[31]32-3c,,,,,,,,,,,,1,42-3d,,,,,,,(),,,,,,,,,,,,,,[31]52-3e132.32.412142-413451-2-3-4-2-4Fig.2-4ProfileofClinchingJoint2.5(a)(b)(c)(d),(e)(f)15a(b)2-5[32]Fig.2-5FailureFormofClinchingJointinDrawingandShear2-5n,2-6ab162-6c2-6d2(1),,Al2O3(2),Al2O3,[14]abcd2-6[21]Fig.2-6FatigueFailureofClinchingJoint2.6171-2-2-7.[19]Fig.2-7.MainGeometryParametersofClinchingJointc1c2h1(t)n2-7c1c2(t)tnh1182.72-82-8Fig.2-8.TechnologyParameterInfluencingClinchingPerformance192.82-9[1,34](a)(b)20c(a)(b)(c)2-9Fig.2-9.FitandUnfitQualityContrastofRivetingForm2.92-10[34]21[2]2-10a[2]2-10b2-10c2-10d[37][1]2-10eabcde2-10Fig.2-10.OtherNewJointingMethod2.102223DEFORM-2D,3.1DEFORM3.1.1DEFORM2070ALPID1990DEFORM-2DSFTCScientificFormingTechnologiesCo.[30]DEFORMDEFORM-2D3DDEFORMDEFORM[38]DEFORM-2DNewton-RaphsonDirectIteration,3DExplicit,3.1.2DEFORMDEFORM[30]12DEFORM-2DDXF/IGSCAD3424567FLOWNET-8DEFORM1(a)(b)(c)(d)(e)2DEFORM3.1.3DEFORM[30]3-1.Fig3-1.SimulationProcessofFormingDEFORM-2DDEFORM-3D(a)(b),(c)25(d)(e)DEFORM3.23.2.1AUTOCADDXFDEFORM-2D3-23-2Fig.3-2.ClinchingGeometryModel263.2.2ecrLtc∆=eLcc=2(1)(12)Gvvρ−−Gvρ[35]()[1,35]1030180204-3[1,35]27(a)1-(b)2-(c)3-3-3.Fig.3-3SeveralBadQualityGrids31DEFORM-2Ddensitywindows0.06mm4-13-102800028000283-4Fig.3-4GridModel3-41.2mm3.2.311913Von.MisesH.Tresca[12][12,39][12,39]2222222()()()()6()2ijxyyzzxxyyzzxsfσσσσσσστττσ=−+−+−+++−()0ijfσ=(3-1)2222222()()()()6()20ijxyyzzxxyyzzxsfσσσσσσστττσ=−+−+−+++−=(3-2)2222()()()()20ijxyyzzxsfσσσσσσσσ=−+−+−−=(3-3)xσyσzσxyτyzτzxτsσ29:()ijfCσ=(3-4)CvonMises()123,,fCσσσ=(3-5)σsσ[39]Tresca313132rσσστ=−=(3-6)Mises2221223314222122313[()(