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针对车身内腔电泳膜厚不足导致生锈,而传统试错方法耗费大量成本、电泳工艺开孔缺乏科学依据等问题,提出了一种能实现车身电泳工艺孔正向设计的新方法——基于电泳仿真的区域分析法。首先基于法拉第电沉积理论,获取电泳过程中的电场、流场信息,搭建电泳电化学仿真环境,建立电泳过程数学模型;构建电泳基础试验模型及其仿真模型,通过试验和仿真结果对比以及参数迭代修正,反求得到对涂料沉积量影响较大的基本沉积参数数值;基于工程上对车身电泳关键区域的划分,确定大梁局部区域典型3层钣金结构为研究对象,构建了大梁局部区域简化结构的电泳电化学全耦合仿真模型,并验证了该模型的准确性。在此基础上,以工艺孔形状、大小为变量,以电化学分析为手段进行研究发现:开孔形状对电泳膜厚几乎无影响,而开孔面积对电泳膜厚有较大影响,分析得到膜厚衰变的数值规律,导出了大梁区域内腔电泳膜厚的安全系数。通过对加强板上双孔叠加效果的分析,进一步推导出该区域孔间距设计的安全系数。最后将量化的研究结果应用于某车大梁区域的结构更改,成功解决了该区域内腔生锈问题。
Aiming at the problem that rust is caused by insufficient film thickness in body cavities, the traditional trial-and-error method consumes a large amount of cost and the scaffolding of electrophoretic process lacks scientific basis, a new method to realize the forward design of bodywork electrophoresis process is proposed. Regional analysis of electrophoresis simulation. Firstly, based on the Faraday electrodeposition theory, the electric field and flow field information in the electrophoresis process was obtained, and the electrophoresis electrochemical simulation environment was set up to establish the mathematical model of the electrophoresis process. The electrophoretic basic experimental model and its simulation model were established. By comparing the experimental and simulation results and the parameter iteration Based on the engineering division of the key areas of the car body electrophoresis, the typical 3-layer sheet metal structure in the local area of the girder is determined as the research object, and the simplified structure of the local area of the girder is constructed Electrochemical Electrochemical Coupling Simulation Model and verify the accuracy of the model. On this basis, taking the shape and size of the process hole as a variable and using electrochemical analysis as a means to study, it is found that the shape of the opening has almost no influence on the thickness of the electrophoresis film while the area of the opening has a greater influence on the thickness of the electrophoresis film. The law of film thickness decay, derive the safety factor of electrophoretic film thickness in the cavity of the girder. By analyzing the double-hole superposition effect on the reinforced board, the safety factor of hole spacing design in this area is further deduced. Finally, the quantitative research results are applied to the structural changes of a car girder area, successfully solved the problem of rust in the cavity of the area.