汽车冲压模具数字化开发及应用
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摘要
汽车冲压模具是汽车行业中一个十分重要的工艺装备。随着汽车行业的飞速发展,产品更新换代的不断加快,汽车冲压模具的设计就越来越需要一种区别于全靠经验、反复试错的传统设计的新方法,来保证汽车冲压件的质量,缩短产品的开发周期。汽车冲压模具数字化开发技术就是这样一种新方法,它包括数字化设计和数字化开发两部分。
通过分析了汽车冲压件产品在生产过程中常会出现的拉裂和起皱两个成形缺陷产生的机理,以及介绍了数字化开发所用到的工具UG和Autoform的理论背景知识,为后面的数字化开发技术的应用打下了理论基础。
结合由重庆数码模车身模具有限公司承担完成的,重庆市科技攻关重大项目——模具关键技术的研究及产业优化中的一个专题,分别从汽车典型的冲压件:1)汽车覆盖件——行李箱外板,2)普通冲压件——顶盖加强框,来说明数字化开发技术应用的先进性、可靠性,并具有一定的行业推广意义。具体内容如下:
1、覆盖件是车身的基本组成部分,其质量优劣对整车性能的影响十分明显。而拉延工艺的好坏又直接影响到整个覆盖件的质量。利用数字化设计技术可以方便的实现拉延工序数模的制作以及修改。
2、针对数字化分析中常出现的问题,通常可以依次采取以下方式进行设计修改:冲压工艺设计、工艺补充面、拉延筋、材料、产品设计变更。
3、零件不同,数字化分析的着眼点和数字化设计难易程度也不同:外板件要求材料完全胀形变形以满足刚度要求,而不产生破裂、滑移,但各工序的模具设计较简单;内板件对次应变要求不严格,但工序模具设计较复杂。
4、数字化分析与设计技术之间相辅相成。分析结果指导设计工艺修改,甚至是产品设计变更;数字化设计好坏取决于分析能否达到要求,最终决定了模具设计的好坏。
The automotive stamping dies are very important tools in auto industry. Along with the booming auto industry and rapid updating of cars, advanced technologies which are different from the traditional trail-and error methods have been developed to ensure quality and reduce development time. The development and application of digital technologies in automotive stamping dies is one of the new technologies. It consists of digital technology of design and digital technology of analysis.
Through two typical case analyses using digital technologies with software UG and Autoform, the thesis analyzed mechanism of defects such as fracture and wrinkle which occur during stamping process. The analysis established theoretical foundation for digital design. As a part of the research project from Chongqing Die and Mould Key Technologies, the research was supported by Chongqing Digidie Auto Body Co., Ltd. Two typical parts of cars were used to illustrate advantage and reliability of the digital technology and potential application in the industry. Of the two examples, one is an exterior panel part—the decklid outer, and the other is an interior part—the stiffing ring of sunroof.
1、The exterior panel parts are the basic parts of the whole car. Their quality influences the whole car’s appearance quite obviously. The draw development directly affects the quality of the panel part. Using the digital technology can help make the draw die more easily and modification more simply.
2、To fix the common problems in the digital technology of analysis, the following changes may needed:Processing of the part, addendum design, draw beads, materials, the product modification.
3、Different parts may have different complexity in design and analysis. For examples, the exterior panels need sufficient stretch, and the sufficient rigidity must be reached while to avoid fracture and surface problem. But the structures of the dies may be relatively simple. The interior parts, on the other hand, may not need good the minor strain but the structures of their dies maybe complicated.
4、Both digital technology of analysis and design complement each other. The analytical results can direct the modification of processing and even product changes. The quality of a stamping die depends on the quality of die design, while the quality of a die design depends on that of the analysis.
通过分析了汽车冲压件产品在生产过程中常会出现的拉裂和起皱两个成形缺陷产生的机理,以及介绍了数字化开发所用到的工具UG和Autoform的理论背景知识,为后面的数字化开发技术的应用打下了理论基础。
结合由重庆数码模车身模具有限公司承担完成的,重庆市科技攻关重大项目——模具关键技术的研究及产业优化中的一个专题,分别从汽车典型的冲压件:1)汽车覆盖件——行李箱外板,2)普通冲压件——顶盖加强框,来说明数字化开发技术应用的先进性、可靠性,并具有一定的行业推广意义。具体内容如下:
1、覆盖件是车身的基本组成部分,其质量优劣对整车性能的影响十分明显。而拉延工艺的好坏又直接影响到整个覆盖件的质量。利用数字化设计技术可以方便的实现拉延工序数模的制作以及修改。
2、针对数字化分析中常出现的问题,通常可以依次采取以下方式进行设计修改:冲压工艺设计、工艺补充面、拉延筋、材料、产品设计变更。
3、零件不同,数字化分析的着眼点和数字化设计难易程度也不同:外板件要求材料完全胀形变形以满足刚度要求,而不产生破裂、滑移,但各工序的模具设计较简单;内板件对次应变要求不严格,但工序模具设计较复杂。
4、数字化分析与设计技术之间相辅相成。分析结果指导设计工艺修改,甚至是产品设计变更;数字化设计好坏取决于分析能否达到要求,最终决定了模具设计的好坏。
The automotive stamping dies are very important tools in auto industry. Along with the booming auto industry and rapid updating of cars, advanced technologies which are different from the traditional trail-and error methods have been developed to ensure quality and reduce development time. The development and application of digital technologies in automotive stamping dies is one of the new technologies. It consists of digital technology of design and digital technology of analysis.
Through two typical case analyses using digital technologies with software UG and Autoform, the thesis analyzed mechanism of defects such as fracture and wrinkle which occur during stamping process. The analysis established theoretical foundation for digital design. As a part of the research project from Chongqing Die and Mould Key Technologies, the research was supported by Chongqing Digidie Auto Body Co., Ltd. Two typical parts of cars were used to illustrate advantage and reliability of the digital technology and potential application in the industry. Of the two examples, one is an exterior panel part—the decklid outer, and the other is an interior part—the stiffing ring of sunroof.
1、The exterior panel parts are the basic parts of the whole car. Their quality influences the whole car’s appearance quite obviously. The draw development directly affects the quality of the panel part. Using the digital technology can help make the draw die more easily and modification more simply.
2、To fix the common problems in the digital technology of analysis, the following changes may needed:Processing of the part, addendum design, draw beads, materials, the product modification.
3、Different parts may have different complexity in design and analysis. For examples, the exterior panels need sufficient stretch, and the sufficient rigidity must be reached while to avoid fracture and surface problem. But the structures of the dies may be relatively simple. The interior parts, on the other hand, may not need good the minor strain but the structures of their dies maybe complicated.
4、Both digital technology of analysis and design complement each other. The analytical results can direct the modification of processing and even product changes. The quality of a stamping die depends on the quality of die design, while the quality of a die design depends on that of the analysis.
引文
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[8] 程迎潮.国内外桥车覆盖件冲压模具设计概览.上海汽车,2004,(5):26-28
[9] Wang, Chuantao. Evolutions of Advanced Stamping CAE - Technology Adventures and Business Impact on Automotive Dies and Stamping. Proceedings of the 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Process. 778(2005), 78—83
[10] 胡轶敏,张卫刚,林忠钦,等.桑塔纳2000型轿车侧框冲压成形.汽车工程,1999,(6):381-386
[11] 黄亚娟,丘宏扬,陈松茂.CAD/CAE/CAM 技术在汽车覆盖件模具中的应用与发展.机电工程技术,2004(5)13-16
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[13] 常江.车身覆盖件成形工艺分析及模拟.CMET 锻压装备与制造技术,2005,(6):50-52
[14] M.Kleiber, J.Rojek, R.Stocki . Realiability assessment for sheet metal forming operations.Computer.Methods Appl. Mech. Engrg. 191(2002)4511—4532
[15] 刁法玺.板料成形过程数值模拟解法研究:[博士学位论文].黑龙江:哈尔滨工业大学,2003.2-9
[16] M.Dyduch, A.M. Habraken and S.Cescotto.Automatic adaptive remeshing for numerical simulations of metalforming.Computer.Methods Appl. Mech. Engrg. 101(1992)283—298
[17] G.C. Bessette, E.B. Becker, L.M. Taylor, D.L. Littlefield.Modeling of impact problems using an h-adaptive, explicit Lagrangian finite element method in three dimensions. Computer Methods Appl. Mech. Engrg. 192(2003)1649—1679
[18] Kjell M.Mathisen, Odd S.Hopperstad, Knut M.Okstad, Torodd Berstad.Error estimation and adaptivity in explicit nonlinear finite element simulation of quasi-static problems.Computers and Structures 72(1999)627-644
[19] T.J.Oetjens. Automotive CAD/CAM Die. The Sculptured Surface Auto FACT. 1987:1—11
[20] 胡道钟,李建华,周洁,等.汽车覆盖件板成形的数值模拟技术及其在车身模具开发中的应用.模具制造,2003,(8):11-14
[21] 徐金波,董湘怀.基于有限元分析的汽车覆盖件模具设计及优化.锻压技术,2004,(1):63-67
[22] 孙立君,黄敏飞,阮锋.汽车覆盖件冲压有限元分析方法及其软件的应用.机电工程技术,2005,(2):18-21
[23] 胡海.汽车覆盖件模具 CAD 技术特点.模具工业,1998,(4):7-10
[24] Nam Ho Kim, Kyung Kook Choi,Jiun Shyan Chen. Die shape design optimization of sheet metal stamping process using meshfree method. International Journal for Numerical Methods in Engineering.2001,(51):1385-1405
[25] 崔令江.汽车覆盖件结构特征与冲压成形性.塑性工程学报,2001,8(2):11-13
[26] 汤荣兵.汽车大型覆盖件拉深工艺性.机械工人,2003,(9):77-78
[27] 吴伯杰.汽车覆盖件拉延工艺补充面优化设计.锻压装备与制造技术,2004,(6):42-44
[28] Gerdeen J C,Chen P. Geometric Mapping Merhod of Computer Modeling of Sheet Metal Forming. Numiform89, Thompson, 1989.Balkema, Rotterdam, ISBN9061918979.
[29] B.T.Check, A.Y.C.Nee. Trends and Develpments in the Automation of Design and Manufacture of Tools for Metal Stampings. Journal of Materials Processing Technology. 1998,(75):204-252
[30] 李正罡.车门外板类冲压件成形工艺的研究:[硕士学位论文].黑龙江:哈尔滨工业大学,2004.25-27
[31] 韩非,万敏,吴向东.板料成形极限理论与实验研究进展.塑性工程学报,2006,(5):80-86
[32] 解后循.材料结构参数对薄板冲压成形仿真结果的影响.金属成形工艺,2003,(2):16-18
[33] 梁云荣.汽车覆盖件拉伸起皱和开裂现象分析及控制措施.模具工业,2001,(6):21-25
[34] 董洪智,林忠钦,陈关龙.轿车侧框冲压仿真计算机辅助造型建模.锻压机械,1998,(4):35-37
[35] 沈启彧，卫原平，王玉国，等．数值腄庠谄蹈哺羌⒅械挠τ醚芯浚>呒际酰?2000,(3):3-8
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