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类似汽车横梁这些复杂管类结构件的充液成形,是一个不均匀的变形过程,坯料的相对形状及尺寸,是影响金属流动的关键因素,从而对充液成形零件的最小壁厚、最大壁厚等评价对象有重要影响。以坯料的弯曲角度、弯曲半径、轴线高度差为因子,建立正交试验设计方案,进行有限元模拟,获得不同坯料尺寸下的最小壁厚、最大壁厚参考序列。利用灰色系统理论,计算各个参考序列与比较序列之间的关联系数,将多目标转化为以关联度为目标的单目标。进一步计算各坯料结构尺寸的平均关联度,获得优化的坯料尺寸组合参数,以此进行有限元模拟和生产实验。验证结果表明,该优化方法能够获得满足质量要求的充液成形的汽车横梁。
Similar to the automobile beams, these complex tube-like structures are filled with liquid and are an inhomogeneous deformation process. The relative shape and size of the billet are the key factors affecting the flow of the metal. Therefore, the minimum wall thickness, Thick evaluation objects have a significant impact. Taking the bending angle, bending radius and height difference of billet as factors, the orthogonal experimental design was established and the finite element simulation was carried out to get the minimum wall thickness and the maximum wall thickness reference sequence under different blank sizes. Using the gray system theory, the correlation coefficient between each reference sequence and the comparison sequence is calculated, and the multi-objective is transformed into a single target with the degree of association as the goal. Further calculate the average degree of correlation of the structure size of each billet, and obtain the optimized billet size combination parameters, so as to carry out the finite element simulation and the production experiment. The verification results show that the optimization method can obtain the liquid-filled automobile cross beam that meets the quality requirements.