A Synchronous Simulation System Of Trimming Line Unfolding And Flanging Integrated Into SolidWorks

Trimming and flanging, one of the most important processes in sheet metal forming, which made assembling, appearance and strengthen are possible, has been widely used in automobile panel and hardware. In the past, both CAD and CAE were applied to module designing of trimming and flanging, while intermediate data format were used for data exchanging between CAD and CAE to aid designing process. In order to avoid the loss of accuracy caused by data conversion and to improve the efficiency of module designing,the analysis function of CAE will be integrated into CAD platform in this thesis.The research of this thesis is supported by National Nature Science Foundation of China project " Research on Fast numerical analysis model and key methods in the strip layout of Progressive die design for complicated Automotive Structural Parts"and China Postdoctoral Science Foundation"Research on the key technology of the sheet metal forming simulation of auto panel in the trimming and flanging processes"and National Science and Technology Major Project"Stamping Dies of the whole body side panels, fenders and interiors of new environmentally friendly materials in C-Class car". More importantly, a synchronous simulation system of trimming line unfolding and flanging was developed based on SolidWorks platform, which realized seamless integration between CAE analysis environment and CAD platform.This research process was mainly focused on the process about how the SW-TUX system was realized. Firstly, the development foundation of the system was deeply studied, based on integration of CAD and CAE, redevelopment of SolidWorks, trimming and flanging process and basic theory of FEM. Then according to the actual process of trimming and flanging and molding features in SolidWorks platform, as well as combined with the solver of finite element inverse approach developed by FASTAMP, the overall framework of the system and the corresponding interface were designed, also the whole development process of the system has been come out. On the basis, the implement principle of key technologies used in the developing process was emphatically studied, including meshing, mesh repair and mesh offset, designing of open material library, the method of defining boundary constraints, parametric and automatic synchronous updating process, and data structure and data storage.The feasibility and widely applicability of the SW-TUX were verified by an example of trimming and flanging simulation. Combined with practical tests, another example of flanging simulation was performed to verify that SW-TUX had good accuracy. The present paper explained and revealed fully that the SW-TUX can be successfully used in the simulation of trimming line unfolding and flanging, and it has high practical value.