Abstract: In order to meet the stricter requirements for appearance accuracy of aluminum alloy automotive bodies, a roller pose compensation method was proposed for the dimensional deviation of automotive bodies. The dimensional deviation matrix was obtained by equidistant discretization of the dimensional deviation interval and the die edge. Based on the Frenet scale frame and Cartesian coordinate transformation, the dimensional deviation was mapped to the roller pose, and the deviation matrix of roller pose was obtained. The roller pose compensation amount was converted into the adjustment amount of the row number of the deviation matrix of roller pose, and the compensated roller pose was obtained. Among them, the deviation matrix of roller pose was determined by the surface/curve equation of die, the roller angle and the quantization model of dimensional deviation and the value of tool center point-robot target point(TCP-RTP). The quantization model of dimensional deviation and the value of TCP-RTP was obtained by finite element simulation of finite element method-smoothed particle hydrodynamics. The results show that the average value of the dimensional deviation is reduced from 0.32mm to 0.14mm after the roller pose compensation.

Key words:  , roller forming, deviation, technological compensation, hemming adhesive

摘要： 针对铝合金车身更严格的外观精度要求，提出一种面向车身尺寸偏差的滚轮位姿补偿方法。首先对尺寸偏差区间与胎模边线进行等距离散，得到尺寸偏差矩阵；然后基于Frenet标架与齐次坐标变换将尺寸偏差映射为滚轮位姿，得到滚轮位姿偏差矩阵；最后将滚轮位姿补偿量转化为滚轮位姿偏差矩阵行编号的调整量，得到补偿后的滚轮位姿。其中，滚轮位姿偏差矩阵由胎模曲面/曲线方程、滚轮倾角，以及FEM-SPH有限元仿真获得的尺寸偏差与TCP-RTP值的量化模型决定。实验结果表明，滚轮位姿补偿后的车身尺寸偏差平均值由0.32 mm降至0.14 mm。

关键词: 滚压成形, 偏差, 工艺补偿, 折边胶