完整版毕业设计外文翻译9570963.docx

完整版毕业设计外文翻译9570963.docx

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完整版毕业设计外文翻译9570963

EvolutionsofAdvancedStampingCAE–

TechnologyAdventuresandBusinessImpactonAutomotiveDiesandStamping

Chuantao（C.T.）Wang

GeneralMotorsCorp.ManufacturingEngineering,DieCenter,2000Centerpoint,Pontiac,MI48341

Abstract.Inthepastdecade,sheetmetalforminganddiedevelopmenttransformedtoascience-basedandtechnology-drivenengineeringandmanufacturingenterprisefromatryout-basedcraft.StampingCAE,especiallythesheetmetalformingsimulation,asoneofthecorecomponentsindigitaldiemakinganddigitalstamping,this.Thestampingsimulationtechnologyanditsindustrialapplications,diedevelopments,dieconstructionandtryout,andproductionstamping.ThestampingCAEcommunityofthestampingCAEtechnologyandbusinessdemandsopensevengreateropportunitiesandchallengestostampingCAEcommunityintheareasof：

（1）continuouslyimprovingsimulationaccuracy,drasticallyreducingsimulationtime-in-system,andimprovingoperationalability（friendliness）,

（2）resolvingthoseandskidimpactlines）,（3）resolvingtotalmanufacturabilityproblemsinlinedieoperationsincludingblanking,drawredraw,trimpiercing,andflanging,and（4）overcomingnewproblemsinformingnewsheetmaterialswithnewformingtechniques.Inthisarticle,theauthorfirstprovidesanoverviewofthestampingCAEtechnologyadventuresandachievements,andindustrialapplicationsinthepastdecade.Thentheauthorpresentsasummaryofincreasingmanufacturabilityneedsfromtheformabilitytototalqualityandtotalmanufacturabilityofsheetmetalstampings.Finally,thepaperoutlinesthenewneedsandtrendsforcontinuousimprovementsandinnovationstomeetincreasingchallengesinlinedieformabilityandqualityrequirementsinautomotivestamping.

INTRODUCTION

Theformingsimulation-basedstampingCAEtechnologyanditsindustrialapplications,diedevelopments,dieconstructionandtryout,andproductionstampinginthepastdecade[1].SincetheNumiSheetConferencestartedin1991,stampingCAEcommunityfundamentalunderstandingofsheetmetalformability,formingmechanics,numericalmethods,butalsothemostsignificantly,thefruitfulindustrialapplicationsinawiderangeofbusinesssegments.

TheautomotivedieandstampingindustrybenefitmostfromthestampingCAE.Thetechnologyadvancementspeedsupainautomotivediedevelopmentandstampingfromatryout-basedcrafttoascience-basedandtechnologydrivenengineeringandmanufacturingenterprise.StampingCAE,especiallythesheetmetalformingsimulation,thistransition[1].InGeneralMotors,thestampingCAEtechnologyextensivelyusedinmanywaystosignificantlyimpactonvariousbusinesssegmentsofvehicleandtoolingdevelopmentprocesses.Theapplicationsandbenefitsaresummarizedasfollowing:

•StampingCAEisusedasaDFMtool（DesignforManufacturability）toassessandvalidatetheproductstylingsurfacedesignstoensuresamanufacturablesheetproductdesignforagoodstartofvehicleprogram.

•Itisusedasadieengineeringtoolinstampinglinediedevelopmentstovalidateandreshapebinderandaddendumoneverynewlineofdies（blanking,draw,trim,flanging,andspringbackresolutions）.

•Itisusedasatryouttooltoreplacesofttoolsandassociatedtryoutsandtoshorten）dietryouttosignificantlyreducediecostandlead-time.

•Itisusedasaproductiontooltoprovideproductionstampingconditions（beadspecifications,lube,bindertonnage,pressload,blankgaging,diesurfacerelief,gripperlocationsforautomation,etc.）.

•Itisusedasaproblemsolvingtoolforproductiontroubleshootingtoreproducemanufacturingproblems,toidentifytherootcausesandtoprovidesolutionsforprocesscontrolimprovements.

•Itisusedasasimulation-basedmanufacturingguidetousetheCAEoutputtodriveconsistencyamongdieengineering,dieconstruction,andproductionstamping.

•Finally,thestampingCAEisusedasalearningtooltoexploreandgainnewknowledgeandapplicationguidancefornewformingtechniques（tubesheetapplicationsjustafewshortyears.

AsmorestampingCAEapplicationdomainsareexplored,themoretechnicallimitationsandinadequaciesarediscovered.Inturn,therecomeapplication-driventechnologydevelopmentandadvancement.Inthispaper,theauthorreviewstheevolutionsofstampingCAEtechnologyanditsindustrialapplicationsinautomotiveproductdesign,diedevelopmentandproductionstamping.Theindustrialneedsfortechnologyimprovementsaredescribed.Thelimitationsofcurrenttechnologyareidentifiedandtheneedsfortechnologydevelopmentsarereviewed.

EVOLUTIONSOFSTAMPINGCAE

StampingCAEtechnologydevelopmentandindustrialapplicationsevolvinginthreemainstages,namely,thefundamentalresearchandlabworkin1970s-1980s,pioneerindustrialtrialsinearlier1990s,andthemassproductionapplicationsaftermid1990sto2000s.

RESEARCHANDDEVELOPMENT（1970S-1980S）

From1970sto1980s,themajordevelopmentswerethefundamentalstudiesofsheetformingmechanics,numericalmodeling,andcomputationalmethods.Theresearchworkwasprimarilyaccomplishedinacademiaandresearchinstitutions.Reference[3]providesacomprehensivereviewoftheresearchworkduringthatperiod.Theresearchtopicswereconcentratedonnumericalformulationssuchasmembranevs.shell,staticimplicitvs.Dynamicexplicit）,toolsheetcontact,materialmodeling（yieldfunctions,workearly1990s,thesheetformingindustry,especiallytheautomotivestamping,attemptedthenumericalsimulationsforlargeandcomplicatedbodypanels.TheBig3sinDetroitledtheworldinthisendeavorbydevelopingtheirproprietarysimulation

toolsforlarge3-dimensionalproblems.Stoughton[8]ofGeneralMotorsdevelopedPanelFormcombiningautomaticmeshgenerationwithmembraneformulationbasedonearlierworkofWangdidwhensametime,Wangledthe

ChryslergroupdevelopedC-FormandTanginFordMotordevelopedMetalForm,andbothcodeswerebasedonshellformulationwithstaticandimplicitsolvers.Othergroupsincludingthecommercialsoftwarevendorsalsodevelopedtheindustrial

orientedsoftware,noticeably,PamstampfromESI（EngineeringSystemsInternational）ofFrance,LSDyna3dfromLSTC（LivermoreSoftwareTechnologyCo.）,bothcodesarebasedonshellformulationanddynamicexplicitsolver,andbothPamstampandLSDyna3D–Dyna3D,apublicdomaincodefromLivermoreLaboratory,aUSAgovernmentfundedresearchinstitution.Theprofessionalconferencesinnumericalsimulationsofmetalformingprocessinearlier1990s,especiallytheNumiSheet[13-17]andNumiForm[18-25]greatlyimprovedourunderstandingofallimportantaspectsoffiniteelementsimulationsofsheetmetalforming.TheNumiSheetConferencesprovidedcomprehensiveexamsforthereadinessofthesimulationtechnologyforindustrialproblems.Themajordifficultiesandchallengesdiscoveredforindustrializationduringthatperiodwere

（1）finiteelementmodeling（robustness（time（tools（suchasPamstampandLS-Dyna3D）withfullshellformulationsanddynamicimplicitsolvers.Thefiniteelementcodeswithone-stepmembraneformulationwerealsogotattentionoftheindustrialusersforthecapabilitiesofusingthelargenumberoffinerelementsandshortcomputationtimealthoughtheaccuracyoftheresultswasquestionable.

TheeconomicdownturnsinUSAinearly1990sandtherecoveryeffortsbytheautomotiveindustry,especiallyGeneralMotorsNorthAmericanOperations,pushedtheapplicationsofmath-basedtoolsandprocessindesign,engineeringandmanufacturing.Bythemidof1990s,thestampingCAEemergedasnewengineeringfieldindieandsheetmetalformingindustry.Anewprofession–stampingCAEengineer,createdsincethen.TheNumiSheet1996DearbornMichiganmarkedthebeginningofmassproductionapplicationsofstampingsimulationsworldwide[15].In1996,afterthreeyearintenseintegratedtechnologydevelopmentandproductionization,GMNorthAmericanStampingcompleteditsinapplyingsimulationbaseddigitalvalidationsforalldrawdiesengineeredandconstructedin—1990s,theindustrialapplicationsofstampingCAEtechnologyweremainlyfocusedonformingsimulationsfordrawdiethatistheoneofthelinediesneededtoformanautomotivepanel.ThestampingCAEcommunitymainlyfocusedonpredictingthetraditionalformabilityproblems（splitsandexcessivethinning,wrinkles）.GMpredictingformabilityproblemswithverydrawdieforming.Fig.1illustratesexcellentcorrelationsbetweenpredictionsandmeasurementsforanaluminumdecklid.Thethinningwasmeasuredverypreciselyusingthepinpointmicronmeteratthesamelocationsidentifiedinsimulations,andthesurfacestrainsweremeasuredbyconventionalcirclegridsthatnormallybands.Thethinningcorrelationisexcellent,andthepredictedmajorandminorstrainsarewithinthemeasurementbands.

FIGURE1.Thinningandstrainsmeasurements

Thinning

FIGURE2.Thinningcomparison

MajorStrain

FIGURE3.Majorstraincomparison

MinorStrain

FIGURE4.Minorstraincomparison

MASSPRODUCTIONAPPLICATIONSANDCHALLENGES（2000s）

Intoday’sdieandstampingindustry,thestampingCAEfordigitalvalidationsofdiedevelopmentsbeforeproductiontrialsisacriticalbusinessforlead-timereduction,costreductionandqualityimprovements.TheindustryandCAEengineerspushthetechnologyenveloplimitandattempttoapplythesimulationstoalmostallpossibleareasofsheetmetalformingtomaximizethepowerofsimulationanditsfinancialbenefits.Intheautomotivestampingaresummarizedasfollowing.

Increasingpartsizeandshapecomplexitysuchaswholebodysidepanels,andmultipleattac