黑龍江工程學院本科生畢業設計 1 附 錄 附錄 A 外文文獻原文 A1 Establish and research on CA/CAE sysytem of automobile drive axle housing based on virtual prototype technology Virtual prototype refer to a model which is in the step of product progress, occurring in the computer realm, aiming at the optimization based on the CAD model used to stimulating analysis product. Virtual prototype in mainly used for test which was failed by physical test. Based on the result which is drawn from the stimulation result, it is easy to modify and guide design, until reach the optimistic design Automobile drive axle housing is a main part of a mobile. disconnect drive axle housing is used for bearing the mobiles weight ,transferring the load to the wheels Drawing force, braking force lateral force and vertical force are transferred to frame and compartment by drive axle housing. So drive axle housing is either a bearing or a transmission item. If not correctly designed or some problem occurred while manufacturing, drive axle housing may deformed or fracture. As a traditional design method is so costly that is necessary to introduce the virtual prototype technology. A1.1 design scheme Traditional design method for drive axle housing is firstly giving a scheme ,manufacturing , a sample item then a series test (such as stiffness test bending fatigue test and static strenth test )is carried out Apparently this method is very money consuming ,and the final parameter may be not optimal .if adopt the Virtual prototype technology stimulazing kinds of working condition of drive axle housing ,and draw a series of optimal parameters .Based on these parameter the physical machine are carried out to do physical test .this method can save time ,cutting the cost ,thus bring in huge benefit to the enterprise. 黑龍江工程學院本科生畢業設計 2 Modern trial production progress vary largely to the traditional one .As depicted ,in the picture ,A loop is absent in the traditional drive axle housing making virtual prototype can assess the cost quality and manufacturability on the computer. If the assessment is not satisfying, it is necessary to adjust .repeat a loop until reach a ideal parameter. This scheme design a software terrace, providing a interface for Solidworks patron and Nastron ,using superiority of this professional software ,and develop these software ,but a drive axle housing product design terrace. Considering the question of improving the analysis efficiency and simplifying finite element ,this system adopt a method which uses parametric modeling that is totally different from do make up for CAD model .And the CAD model is only used for oversight A1.2 Parameterized Modeling by SolidWorks They are all available for second-time development of SolidWorks for the softwares that support OLE and COM. Because of design requirements, the development software of the system is Delphi and second development software of SolidWorks is OLE. The copyright of SolidWorks is 2006. To use this method, it must be registered for auto-severed including files sldworks.tlb and element files that filenames are SldWorks_TLB.pas severed by SolidWorks under Delphi program environment, and they are available after programs are complied. The topology structure of SolidWorks is typically five layers topology structure. A part is consist of bodies, and bodies include surfaces, and surfaces include edges, and edges include curves and points. It may use record in delphi to define bodies, surfaces and points these data structure and apply respectively to store topology information. The steps of the parameterized modeling of CAD by SolidWorks are as follows: firstly, it must be defined correctly for the relationship between automobile dimension and other dimensions. Secondly, initialize the various record and auto-product the drawing of axle housing using API function. Lastly, it is available for users to check the CAD model and modify various dimensions on the plate. The program can auto-modify the other relative dimensions and 黑龍江工程學院本科生畢業設計 3 redraw the picture in SolidWorks by using the relationships that have been defined previously. A1.3 Patran & Nastran FEA analysis A1.3.1 PCL program MSC/PATRAN provides a fully functions program language for users, as PCL. PCL provide abundant of tables and menus and allow users to read and write all information in Patran database, which structure is similar with C language. The paper develops the analysis module of the automobile drive axle housing, which includes parameterize modeling, ALE, material definition, load cases definition, Nastran analysis submitted and results post-possessing and other functions. There are no special develop environment in PCL, generally the codes are written in test editor and saved as *.pcl format, and then the files are pre-compiled as *.cpp format in DOS, and debug them in Patran at last. The detail operates are as follows: Pre-compile *.pcl file: cpp *.pcl *.cpp debug *.cpp file in patran: !input *.cpp When starting, Patran will execute init.pcl file under its root catalogue. The file includes two commands:!INPUT p3prolog.pcl and !IPUT p3epilog.pcl. As pre-compile these two files when Patran starts. Users can write commands to initialize Patran starting viewport. For example, write commands： !iput C:MSC.SoftwareMSC.Patran2005_r2 rearhouse.cpp and rearhouse.init() in p3epilog.pcl, in which, rearhouse.cpp is the second-time development program for automobile drive axle housing. It will influence the starting speed, for this, users can write self-definition functions and compile them into a database, which Patran can call directly. The method is that: Input commands in Patran: !COMPLIE rearhouse.cpp into rearhouse.plb 黑龍江工程學院本科生畢業設計 4 !library rearhouse.plb !llibrar keepopen rearhouse.plb As this, Patran can load including files when it starts and the speed is rather fast. For initialize the viewport, users need to input that: rearhouse,init(). A1.3.2 Program Design Flowchar The FEA parameterize modeling part is implemented as follows: Input various key parameters into delphi, and they will be compiled and format a file whose suffix is .cpp. The contents of init.pcl can be modified by dephi. As that, users can enter Patran by click “FEA parameterize modeling” in this system, and they will see a new file, whose drawing zone has complete FEA module. The program parts dont need to communicate with users and just like a back program. In this progress it will need API function of Windows system. Due to they require high communicate for ALE, material definition, load cases definition, Nastran analysis submitted and results post-possessing and other functions, which are not convenient for delphi to control directly, these parts will be written by PCL. Patran may copy the .CPP files to the catalog such as “C:MSC.SoftwareMSC.Patra2005_r2”, and modify the relative contents in init.pcl file. Allowing for the special features of housing modeling and computing speed of computers, the program all use shell elements to simulate housing. Therefore it use sgm_const_surface_extrude() to product shell function when modeling, and use fem_create_mesh_surf_4() to mesh when FEA meshing. A1.4 Software application example This software is established by the delphi computer language. After enter the system, preliminary design of automobile drive axle housing by basis mechanics must be completed to define the key dimension, then CAE/CAD modeling and analyzing of various operating conditions should be starting. The software interface is shown in the Figure A1, Figure A2 shows the solid model of axle housing by SolidWorks parameterized modeling. 黑龍江工程學院本科生畢業設計 5 Figure A1 The software interface Figure A2 The solid model of axle housing Table A1 illustrates material parameters which Component Material Modulus of elasticity Poisson ratio Density Drive axle housing QT400-15 1.962E8 KPa 0.3 7.8E-6 kg/mm3 Half axle casing 45Mn2 2.1E8 KPa 0.28 7.9E-6 kg/mm3 Five operating conditions are analyzed by Patran&Nastran in this system, which are shown in Figure A5, static of 2.5 times full load, driving by the maximum drawing force, brake of full load, turning around of full load, brake of full load in turning around. Longitudinal direction, side direction, vertical direction and revolve of longitudinal 黑龍江工程學院本科生畢業設計 6 direction constraints are laid on at the center of steel plate spring. Load is laid on at the half axle casing, which resulting stress is inconsistent with actual condition, bringing no impact on stress of other parts of axle housing. The result shows that Tresca stress on wheel side is larger in Table A3. Table A2 The stress of axle housing of 5 operating conditions Static of 2.5 times full load Driving by the maximum drawing force Brake of full load Turning around of full load Brake of full load in turning around Stress in critical section 175 87 93.5 158 205 The allowable stress of axle housing is 400MPa, the design is very safe, which shown in the Table A2. Figure 8 illustrates the distribution of stress nearby the steel plate spring. Figure A3 The distribution of stress nearby the steel plate spring Table A3 illustrates the former 9th order natural frequency of automobile drive axle housing by this system. Table A3 The former 9th order natural frequency Order 1 2 3 4 5 6 7 8 9 Frequency 181.47 265.91 433.24 614.33 658.76 1119.9 1166 1347.4 1399.6 Since the road is not absolutely smooth, automobile natural frequency often occur between 120Hz. Resonance of axle housing wont be caused. This result is reasonable. 黑龍江工程學院本科生畢業設計 7 Figure A4 The 1st order mode of vibration 附錄 B 外文文獻中文翻譯 A1 基于虛擬樣機技術的汽車驅動橋橋殼 CAD/CAE 系統的建立于研究 虛擬樣機是指在產品設計階段，在計算機世界中，以優化設計思想為指導，以產品 CAD 模型為基礎，利用各種相關 CAE 分析軟件，進行產品主要性能仿真分析的數字模型。虛擬樣機主要進行對物理樣機而言難以進行的試驗，根據虛擬樣機反饋的仿真結果，修正、指導設計，直至獲得系統級的優化設計方案 。 驅動橋橋殼是汽車上主要零件之一，非斷開式驅動橋殼起著支承汽車荷重的作用，并將載荷傳給車輪。作用在驅動車輪上的牽引力、制動力、側向力和垂向力也經過橋殼傳到懸架及車架或車廂上。因此，橋殼既是承載件又是傳力件。如設計不當或制造工藝有問題時，會使橋殼變形或折斷。傳統橋殼設計方法代價過于昂貴，因此有必要引進虛擬樣機技術。 A1.1 設計方案 以往的橋殼設計方法都是先提出一種方案，制造出物理樣機，然后通過剛度試驗、靜強度試驗、彎曲疲勞壽命試驗等多次破壞性的物理試驗來確定其性能參數、材料特性。顯然這種方法的代 價是相當昂貴的，而且最后得出的參數也不一定是最優的。如果采用虛擬樣機技術先對驅動橋橋殼工作的各種工況進行仿真，在計算機里面通過參數優化得出一組合理的設計參數值，然后再根據這組合理的參數值制造出物理樣機做黑龍江工程學院本科生畢業設計 8 物理試驗。這種方法節省時間，降低成本，將為企業帶來巨大的經濟效益。 現代模式的新產品試制過程，和傳統的新產品試制過程有很大不同。 A 循環部分為汽車驅動橋橋殼新產品試制傳統方法中所無，即虛擬樣機部分。虛擬樣機可對設計質量、成本、可制造性（制造工藝性）等指標在計算機上進行評價，當評價不滿意時，進行修改設計，重復 A 循 環，直到獲得理想的參數為止。 本方案設計開發一個軟件平臺，提供 SolidWorks、 Patran&Nastran 的接口，利用兩種專業應用軟件在 CAD 建模和有限元分析方面的優勢，分別對二者進行二次開發，建立一個針對汽車驅動橋橋殼產品的數字化設計平臺。 考慮到提高有限元軟件的分析效率和有限元模型的簡化問題，本系統采用在Patran 中單獨參數化建模的方法，而不是直接修改簡化 CAD 模型，而 CAD 模型只用于觀察裝配干涉和生成二維生產圖。 A1.2 SolidWorks 參數化建模 凡支持 OLE 和 COM 編程的開發工具均可 用于 SolidWorks 的二次開發。由于設計需要本系統采用 Delphi 作為開發工具，運用 OLE 自動化技術對 SolidWorks 進行二次開發。 SolidWorks 版本為 2006 版。采用這種方法必須在 Delphi 編程環境中注冊由SolidWorks 提供的自動化服務類型庫文件 sldworks.tlb，生成名為 SldWorks_TLB.pas的單元文件，并在編譯程序時引用之方可。 SolidWorks 的拓撲結構為典型的五層式拓撲結構。一個零件對象由體構成，體中含面，面中含邊，邊中含曲線和頂點。可用 delphi 中的 record 記錄定義體、面、點數據結構，分剔用于存儲各自拓撲信息。在 SolidWorks 中 CAD 參數化建模過程如下：首先，定義好驅動尺寸和其余尺寸間的關系。其次，初始化各 record，利用 API 函數自動生成橋殼實體圖形。最后，用戶可以在本軟件平臺上檢查 CAD 模型并修改各尺寸參數，程序利用預先定義好的各尺寸間的關系，自動修改橋殼其余相關尺寸，在SolidWorks 中重畫橋殼圖形。 A1.3 Patran&Nastran 有限元分析。 A1.3.1 PCL 編程 MSC/PATRAN 為用戶提供了一種全功能的編程語言， 即 PCL(PATRAN command 黑龍江工程學院本科生畢業設計 9 language)lsi。 PCL 提供了豐富的表格和萊單庫，使用戶可以方便快捷的編制 Motif 界面，允許用戶讀寫 Patran 數據庫中的全部信息，其結構和 C 語言類似。本文利用 PCL語言開發包括參數化建模、自動網格劃分、定義材料、定義工況、提交 Nastran 分析和結果后處理等功能的汽車驅動橋橋殼分析模塊。 PCL 沒有專門的集成開發環境，一般都是在文本編輯器中編寫代碼，并將文本保存為 *.pcl 格式，然后在 DOS 環境中將文件預編譯為 *.cpp 格式，最后在 Patran 中調試*.cpp 文件。具體操作如下： Patran 每次啟動都會執行其根目錄下的 init.pcl 文件，該文件中包含兩個命令：！ !INPUT p3prolog.pcl 和！ !INPUT p3epilog.pcl。即在 Patran 啟動時預編譯p3prolog.pcl 和 p3epilog.pcl 文件。用戶可以在此二文件中寫入命令初始化 Patran 啟動界 面 。 如 在 p3epilog.pcl 中 寫 入 命 令 ： ！ ！ input C: MSC.SoftwareMSC.Patran2005_r2rearhouse.cpp 和 rearhouse.init0，其中 rearhouse.cpp為汽車驅動橋橋殼分析二次開發程序。會影響 Patran 的啟動速度，用戶可以先將自己編寫的函數編譯到一個數據庫中， Patran 可直接調用。方法如下： 在 Patran 命令行中輸入如下命令： ！ !COMPILE rearhouse.cpp into rearhouse.plb $編譯形成用戶化庫 在 init.pcl 文件中輸入如下內容： ！ !library rearhouse.plb ! !library keepopen rearhouse.plb 如此， Patran 肩動時自動 加載庫文件，速度很快，用戶要初始化界面只需在命令行中輸入： rearhouse.init0。 按有限元分析一般流程，本文有限元參數化建模部分的實現如下： 在 delphi 中輸入各關鍵參數，經過 delphi 編譯后生成一個后綴名為 .cpp 的文件，并由 delphi 程序控制修改 init.pcl 文件內容，初始化 Patran。即用戶從此軟件系統中點擊“有限元參數化建模”按鈕就會自動進入 patran 中，并看到一個新建的文件，其繪圖區中已有自動建模完畢的有限元分析模型。在 Patran 看來這部分程序不需要同用戶黑龍江工程學院本科生畢業設計 10 交互操作，就像一個 后臺程序。在此過程中需用到 Windows 系統的 API 函數。 其余網格劃分、定義工況、定義材料、提交 nastran 分析、后處理等工作需要很高昀交互性，不便由 delphi 程序直接控制，因此實現這一部分功能的 PCL 程序單獨編寫。delphi 只 將 編 譯 好 的 實 現 這 部 分 功 能 的 .cpp 文 件 拷 貝 到 如 “ C: MSC.S