基于热成形高强钢板的车身结构轻量化分析与优化
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摘要
汽车车身结构设计和制造业不断发展新材料和新技术以适应轻量化设计的要求。具有强度、刚度、抗冲击性、回收使用和低成本等方面综合优势的高强度钢板在车身轻量化设计中得到越来越广泛的关注。本文以轻质高强度钢为对象，进行了基于热问题的性能研究、成形性分析，并以某自主品牌轿车车身为载体，采用建立的MSOT方法（M－多维因数车身模型、S－构件筛选、0－板厚多目标优化、T－实验验证）进行了结构轻量化分析和优化问题的系统研究。
从表面形貌和成分能谱、心部的显微组织和成分能谱，对高强度热成形钢的微观组织进行了实验研究，并对比分析了未加热和加热后的显微组织和成分；以铁碳合金相图为基础，对亚共析钢类型的热成形钢进行了热处理工艺理论分析和热模拟试验的研究，获得了高强度硼化钢的CCT曲线。通过冷态拉伸试验和热模拟试验，测试分析了热成形硼钢在不同温度、不同变形速率下力学性能，并采用幂指数本构方程对常温和淬火后的应力应变曲线进行了拟合，采用热态材料模型对高温状态下应力应变曲线进行了拟合。通过高温成形极限试验，研究了热成形硼钢分别在600℃、700℃、800℃的成形极限，得到了成形极限图。
针对轻量化车身的高强度结构件热成形问题，研究了热成形过程的数值模拟和工艺参数的优化。给出了热冲压成形方案流程，说明了热成形数值模拟中的热处理、相变和成形过程之间关系，分析了热冲压有限变形理论，热力学参数的关系和求解算法；建立了典型的车身部件热冲压的力学模型和有限元分析模型，并进行了部件的展开反求分析、热成形仿真求解和成形性结果的分析评价。
热成形高强度钢的采用将使在车身结构的材料构成更加复杂，材料的强度等级范围更宽，这就使得车身结构的设计与分析应该具有对应的方法。针对轻量化车身结构性能目标问题，系统的进行了多维因数下车身结构仿真分析，主要包括：建立了车身结构的刚度、模态CAE模型，对它们进行了弯曲刚度、扭转刚度、模态特性分析和评价；建立了车身结构强度CAE模型，对它们进行了各极限工况下的结构强度分析和评价；建立了整车碰撞CAE模型，对车身结构进行了40%ODB偏置碰撞和侧面碰撞仿真分析和评价。通过对车身结构在碰撞和极限工况等情况下的受力特征分析、各构件板厚灵敏度分析计算,得到了车身结构高强度钢板的分布规律，筛选出了轻量化优化的目标零部件。
由于热成形高强度钢板的使用，车身构件的钢板进一步变薄，而且全车将由不同强度和厚度的钢板所构成，因此研究板厚对结构性能的影响将更加重要。由此分析总结了车身板厚结构多目标优化的基本理论和优化算法的相关技术体系、综合减重流程和方法。以此为基础，分别建立了基于静动态性能近似模型和轻量化优化数学模型、基于正面偏置碰撞安全性的近似模型和轻量化优化数学模型、基于侧面碰撞安全性的近似模型和轻量化优化数学模型，并采用非支配多目标遗传算法NSGA-Ⅱ对数学优化模型进行了求解计算，分别得到了结构质量和扭转刚度、结构质量和吸能、结构质量和加速度的Pareto解集。分别选取其中两种方案代入到有限元模型中计算，并与优化前仿真结果进行对比分析，研究表明优化的方法和结果是可行和有效的。
通过白车身模态试验和仿真结果对比研究、40%ODB偏置实车碰撞试验和仿真结果对比研究、侧面实车碰撞试验和仿真结果对比研究，结果表明，在前述分析过程中建立的白车身和整车碰撞CAE模型是满足综合工程模拟仿真精度要求的。对车身结构多目标优化解，从疲劳强度、正面碰撞安全性、侧面碰撞安全性等角度对优化减重后两方案进行仿真分析，并与优化前的初始模型仿真计算结果进行对比研究，验证了轻量化车身板厚结构多目标优化的综合效果。
In order to satisfy the demand of vehicle lightweight design, the automobiledesign and manufacturing industry are keeping developing new materials andtechnologies. High-strength steel is receiving more and more attention, because of itsadvantage in strength, stiffness, impact resistance, recoverability and cost. In thispaper, light high-strength steel is taken as an object to carry out properties study andforming study on thermal problem; and an independent brand sedan body is taken as acarrier for lightweight structural analysis and optimization based on the MSOTmethod established.
This paper studies the microstructure of high-strength hot forming steel by itssurface morphology and component spectrum, the core microstructure and componentspectrum. And we compare the microstructure and components before and afterheating. Based on the iron-carbon alloy phase diagram, this paper studies theheat-treatment process theory and thermal simulation on hypo-eutectoid hot formingsteel, and acquires the CCT curve of high-strength boronization steel. We test andanalyze the mechanical performance of hot forming boronization steel in differenttemperatures and shape-changing rates by means of cold-state tensile experiment andthermal simulation, and fit the stress-strain curve in normal temperature and afterquenching and the stress-strain curve in high temperature, with the help ofexponential constitutive equation and thermal state model respectively. We also studythe forming limit of hot forming boronization steel in600℃,700℃and800℃, andacquire forming limit diagram.
According to the forming difficulty of high-strength structural parts, this paperstudies the numerical simulation and process parameters optimization among hotforming process. A hot stamping process is presented in this paper. And this paper alsoexplains the relationship among heat-treatment, phase transition and forming processin hot forming numerical simulation, and analyzes hot stamping finite deformationtheory, the relationship of thermodynamic parameters and solution algorithm. Besides,this paper establishes a hot stamping mechanical model and finite element analysismodel of a typical automotive body parts, and analyzes the parts expansion reverse,hot forming simulation solution and formability result.
Using high-strength hot forming steel will make material composite more complex and strength grade range wider. It needs corresponding methods to solvethese two problems. In order to propose the performance objectives of lightweightautomotive body structure, this paper builds a strength and modal CAE model, andanalyzes and evaluates its bending stiffness, torsional stiffness and modalcharacteristics. This paper also builds an automotive body structure strength CAEmodel to study its structural strength under different limiting conditions. A whole carimpact CAE model is built to analyze and evaluate the40%ODB offset impact andside impact performance. After that, the mechanics characteristic distribution ofautomotive body structure high-strength steel is obtained, which can help to selecttarget parts for lightweight optimization.
Steel plate used in vehicle body component will be thinner if using high-strengthhot forming steel. The whole body will be composed by different strength anddifferent thickness steel plate, so it’s very important to study how the thickness affectsstructural performance. Based on the basic theory of automotive body multi-objectiveoptimization and some related technology system about optimization algorithm, webuild approximate models and lightweight optimization mathematic models ondynamic and static performance, safety performance in frontal offset impact and sideimpact, and acquire the Pareto solution set of structural quality and torsional stiffness,structural quality and energy-absorbing, and structural quality and acceleration,respectively. Two projects are selected to carry on finite element model simulation.The result is compared with the simulation result before optimization, which showsthe optimization method works effectively.
The comparisons between the test and simulation of BIW modal model and twocollision models show both the BIW model and whole car collision CAE modelsatisfy simulation precision demand. From different aspects, such as fatigue strength,safety performance in frontal impact and side impact, this paper compares thesimulation result of these two projects before and after optimization, which verifiesthe comprehensive effect of lightweight automotive body multi-objectiveoptimization.
从表面形貌和成分能谱、心部的显微组织和成分能谱，对高强度热成形钢的微观组织进行了实验研究，并对比分析了未加热和加热后的显微组织和成分；以铁碳合金相图为基础，对亚共析钢类型的热成形钢进行了热处理工艺理论分析和热模拟试验的研究，获得了高强度硼化钢的CCT曲线。通过冷态拉伸试验和热模拟试验，测试分析了热成形硼钢在不同温度、不同变形速率下力学性能，并采用幂指数本构方程对常温和淬火后的应力应变曲线进行了拟合，采用热态材料模型对高温状态下应力应变曲线进行了拟合。通过高温成形极限试验，研究了热成形硼钢分别在600℃、700℃、800℃的成形极限，得到了成形极限图。
针对轻量化车身的高强度结构件热成形问题，研究了热成形过程的数值模拟和工艺参数的优化。给出了热冲压成形方案流程，说明了热成形数值模拟中的热处理、相变和成形过程之间关系，分析了热冲压有限变形理论，热力学参数的关系和求解算法；建立了典型的车身部件热冲压的力学模型和有限元分析模型，并进行了部件的展开反求分析、热成形仿真求解和成形性结果的分析评价。
热成形高强度钢的采用将使在车身结构的材料构成更加复杂，材料的强度等级范围更宽，这就使得车身结构的设计与分析应该具有对应的方法。针对轻量化车身结构性能目标问题，系统的进行了多维因数下车身结构仿真分析，主要包括：建立了车身结构的刚度、模态CAE模型，对它们进行了弯曲刚度、扭转刚度、模态特性分析和评价；建立了车身结构强度CAE模型，对它们进行了各极限工况下的结构强度分析和评价；建立了整车碰撞CAE模型，对车身结构进行了40%ODB偏置碰撞和侧面碰撞仿真分析和评价。通过对车身结构在碰撞和极限工况等情况下的受力特征分析、各构件板厚灵敏度分析计算,得到了车身结构高强度钢板的分布规律，筛选出了轻量化优化的目标零部件。
由于热成形高强度钢板的使用，车身构件的钢板进一步变薄，而且全车将由不同强度和厚度的钢板所构成，因此研究板厚对结构性能的影响将更加重要。由此分析总结了车身板厚结构多目标优化的基本理论和优化算法的相关技术体系、综合减重流程和方法。以此为基础，分别建立了基于静动态性能近似模型和轻量化优化数学模型、基于正面偏置碰撞安全性的近似模型和轻量化优化数学模型、基于侧面碰撞安全性的近似模型和轻量化优化数学模型，并采用非支配多目标遗传算法NSGA-Ⅱ对数学优化模型进行了求解计算，分别得到了结构质量和扭转刚度、结构质量和吸能、结构质量和加速度的Pareto解集。分别选取其中两种方案代入到有限元模型中计算，并与优化前仿真结果进行对比分析，研究表明优化的方法和结果是可行和有效的。
通过白车身模态试验和仿真结果对比研究、40%ODB偏置实车碰撞试验和仿真结果对比研究、侧面实车碰撞试验和仿真结果对比研究，结果表明，在前述分析过程中建立的白车身和整车碰撞CAE模型是满足综合工程模拟仿真精度要求的。对车身结构多目标优化解，从疲劳强度、正面碰撞安全性、侧面碰撞安全性等角度对优化减重后两方案进行仿真分析，并与优化前的初始模型仿真计算结果进行对比研究，验证了轻量化车身板厚结构多目标优化的综合效果。
In order to satisfy the demand of vehicle lightweight design, the automobiledesign and manufacturing industry are keeping developing new materials andtechnologies. High-strength steel is receiving more and more attention, because of itsadvantage in strength, stiffness, impact resistance, recoverability and cost. In thispaper, light high-strength steel is taken as an object to carry out properties study andforming study on thermal problem; and an independent brand sedan body is taken as acarrier for lightweight structural analysis and optimization based on the MSOTmethod established.
This paper studies the microstructure of high-strength hot forming steel by itssurface morphology and component spectrum, the core microstructure and componentspectrum. And we compare the microstructure and components before and afterheating. Based on the iron-carbon alloy phase diagram, this paper studies theheat-treatment process theory and thermal simulation on hypo-eutectoid hot formingsteel, and acquires the CCT curve of high-strength boronization steel. We test andanalyze the mechanical performance of hot forming boronization steel in differenttemperatures and shape-changing rates by means of cold-state tensile experiment andthermal simulation, and fit the stress-strain curve in normal temperature and afterquenching and the stress-strain curve in high temperature, with the help ofexponential constitutive equation and thermal state model respectively. We also studythe forming limit of hot forming boronization steel in600℃,700℃and800℃, andacquire forming limit diagram.
According to the forming difficulty of high-strength structural parts, this paperstudies the numerical simulation and process parameters optimization among hotforming process. A hot stamping process is presented in this paper. And this paper alsoexplains the relationship among heat-treatment, phase transition and forming processin hot forming numerical simulation, and analyzes hot stamping finite deformationtheory, the relationship of thermodynamic parameters and solution algorithm. Besides,this paper establishes a hot stamping mechanical model and finite element analysismodel of a typical automotive body parts, and analyzes the parts expansion reverse,hot forming simulation solution and formability result.
Using high-strength hot forming steel will make material composite more complex and strength grade range wider. It needs corresponding methods to solvethese two problems. In order to propose the performance objectives of lightweightautomotive body structure, this paper builds a strength and modal CAE model, andanalyzes and evaluates its bending stiffness, torsional stiffness and modalcharacteristics. This paper also builds an automotive body structure strength CAEmodel to study its structural strength under different limiting conditions. A whole carimpact CAE model is built to analyze and evaluate the40%ODB offset impact andside impact performance. After that, the mechanics characteristic distribution ofautomotive body structure high-strength steel is obtained, which can help to selecttarget parts for lightweight optimization.
Steel plate used in vehicle body component will be thinner if using high-strengthhot forming steel. The whole body will be composed by different strength anddifferent thickness steel plate, so it’s very important to study how the thickness affectsstructural performance. Based on the basic theory of automotive body multi-objectiveoptimization and some related technology system about optimization algorithm, webuild approximate models and lightweight optimization mathematic models ondynamic and static performance, safety performance in frontal offset impact and sideimpact, and acquire the Pareto solution set of structural quality and torsional stiffness,structural quality and energy-absorbing, and structural quality and acceleration,respectively. Two projects are selected to carry on finite element model simulation.The result is compared with the simulation result before optimization, which showsthe optimization method works effectively.
The comparisons between the test and simulation of BIW modal model and twocollision models show both the BIW model and whole car collision CAE modelsatisfy simulation precision demand. From different aspects, such as fatigue strength,safety performance in frontal impact and side impact, this paper compares thesimulation result of these two projects before and after optimization, which verifiesthe comprehensive effect of lightweight automotive body multi-objectiveoptimization.
引文
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