目的 探索出一种适用于工程应用的模具与铆钉选型方法。方法 利用ABAQUS软件建立了厚度2 mm的6061-T6铝合金自冲铆接成形精细化模型,并基于此模型研究了工艺参数对接头质量的影响。采用参数识别方法逆向获取了不同硬度铆钉的材料参数,并通过实验验证了精细化模型的准确性;探究了平底凹模尺寸对接头截面尺寸与底部形貌的影响;基于优化凹模尺寸,探究了铆钉长度、铆钉硬度对自冲铆接接头质量的影响规律。结果 试验与仿真的接头截面尺寸误差控制在7%以内,建立的模型能够较为准确地模拟自冲铆接成形过程;底切量、腿部张量与凹模深度呈正相关,底厚值与凹模深度呈负相关,其中当凹模深度为1.6 mm时,接头截面尺寸最好且底部无裂纹;由单搭接拉剪与十字拉伸试验可知,当铆钉长度为6 mm、硬度为H4时,接头质量最好,其抗拉剪力、抗拉伸力分别为8.3 kN、4.3 kN,对应的失效位移为4.3 mm、8.9 mm。结论 所提出的有限元仿真与实验验证相结合的选型方法克服了经验法耗时长、成本高的问题,能够精准高效选出最佳模具-铆钉组合,具有较强的工程实用性。
Abstract
The work aims to explore a method for selecting appropriate molds and rivets for engineering applications. A refined model of self-pierce riveting forming of 6061-T6 aluminum alloy with a thickness of 2 mm was established using ABAQUS software, and the influence of process parameters on the quality of joints was investigated based on this model. The material parameters of rivets with different hardness were obtained inversely by using the parameter identification method, and the accuracy of the refined model was verified through experiments; The influence of the flat-bottomed concave die size on the cross-sectional size and bottom morphology of the joints was investigated; and the influences of the length of rivets and the hardness of rivets on the quality of the joints were investigated based on the optimization of the concave die size. The results showed that the error of the joint cross-sectional size between test and simulation was controlled within 7%, and the established model could accurately simulate the forming process of self-pierce riveted joints; The bottom cut and leg tension were positively correlated with the depth of concave die, and the bottom thickness was negatively correlated with the depth of concave die, in which when the depth of the concave die was 1.6 mm, the cross-sectional size of the joint was the best and the bottom was free of cracks; it could be seen from the single-lap tensile shear and cross tensile tests that the riveted joint quality and bottom morphology were affected by the optimized concave die size, and the length of rivets and hardness of rivets was 6 mm. When the rivet length was 6 mm and the hardness was H4, the quality of the joint was the best, and its tensile shear and tensile forces were 8.3 kN and 4.3 kN, respectively, and the corresponding failure displacements were 4.3 mm and 8.9 mm. The proposed method based on the combination of finite-element simulation and experimental validation overcomes the problems of the empirical method of long time-consuming and high cost, and is able to accurately and efficiently select the optimal mold-rivet combinations with high engineering practicality.
关键词
6061-T6铝合金 /
自冲铆接成形模拟 /
参数识别 /
铆模与铆钉选型 /
接头质量评价 /
力学性能试验
Key words
6061-T6 aluminum alloy /
self-pierce riveting simulation /
parameter identification /
riveting die and rivet selection /
evaluation of connector quality /
mechanical performance test
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基金
中央高校基本科研业务费专项资金（SWU7130200010/076）; 国家自然科学基金（51975479,52174374）
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