汽车钢板冲压成形表面损伤规律与控制方法研究
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摘要
为适应现代汽车轻量化、安全性和耐腐蚀性等发展趋势，高强度钢板和镀锌钢板在汽车上的应用越来越多。但高强度钢板和镀锌钢板在冲压过程中也遇到了诸多挑战，如高强度钢板冲压成形时由于需要更大的压边力和拉深力，在成形过程中更容易引起板料表面损伤，镀锌钢板在冲压加工中也出现了镀层粉化、脱落和龟裂等表面损伤缺陷。板料表面损伤不仅影响了汽车的使用性能，而且加速了模具磨损，破坏了冲压工艺稳定性，提高了汽车制造成本。因此研究高强度钢板和镀锌钢板在冲压成形中的表面损伤行为，揭示各影响因素对板料表面损伤的影响规律，抑制或减轻高强度钢板和镀锌钢板表面损伤，对推广高强度钢板和镀锌钢板的工程应用、降低汽车制造成本有着重要的理论意义和实际价值。
本文在借鉴和吸收国内外先进研究成果的基础上，针对高强度钢板和镀锌钢板在冲压成形中的表面损伤现象进行了系统研究。首先根据板料冲压加工中的变形、摩擦等特点以及板料表面损伤的特征建立板料表面损伤物理模拟实验及评价系统；在此基础上研究模具和工艺等因素对高强度钢板表面损伤的影响规律，建立高强度钢板表面损伤演化模型；接着研究不同模具硬度条件下钢板强度对板料表面损伤的影响规律，建立可抑制表面损伤缺陷的钢板与模具硬度匹配窗口；最后研究镀锌钢板表面损伤规律以及镀锌工艺对镀锌板表面损伤类型的影响，揭示镀锌钢板表面损伤特点以及产生机理。本文的主要研究内容如下：
（1）针对钢板冲压加工特点的板料表面损伤物理模拟实验研究
由于车身覆盖件冲压成形中钢板的塑性变形行为以及变形模式的复杂性，使用传统摩擦实验装置不能模拟钢板与模具间的接触摩擦。首先分析车身覆盖件冲压成形中钢板与模具间的接触摩擦特点以及板料表面损伤特征，设计一具有多种板料变形模式的复杂零件来研究钢板冲压加工中的板料表面损伤。为进一步研究模具、工艺及板料因素对板料表面损伤的影响规律，设计带拉延筋的U形件来模拟钢板在拉伸-弯曲变形模式下的表面损伤现象。最后基于车身覆盖件生产现场工况，制定钢板表面损伤影响因素变化范围，设计板料表面损伤模拟实验方案，并研究板料表面损伤定量评价参数及其测量方法。
（2）高强度钢板表面损伤规律及其演化模型建立
以高强度钢板B170P1为研究对象，首先研究模具材料Cr12MoV、Mo-Cr合金铸铁、球墨铸铁和灰铸铁对钢板表面损伤的影响，结果表明，Mo-Cr合金铸铁是适合高强度钢板冲压成形的最优模具材料。接着使用不同硬度、粗糙度水平的Mo-Cr合金铸铁模具，研究模具和工艺条件等因素对钢板表面损伤的影响规律，得出可以通过提高模具硬度、模具表面粗糙度等级以及适当减小压边力等措施来减轻板料表面损伤缺陷。最后在物理模拟实验数据的基础上，建立高强度钢板表面损伤演化模型，并验证了模型的正确性。利用本部分的研究内容，可以综合考虑模具及工艺等因素来制定技术措施，进而抑制或减轻板料表面损伤缺陷。
（3）面向高强钢板表面损伤的板材与模具硬度匹配窗口建立
随着钢板强度水平的提高，钢板冲压成形需要更高的压边力，冲压加工中更容易引起板料表面损伤，而且由于钢板硬度的提高，模具磨损也更严重。因此，对于不同强度等级的高强度钢板冲压成形，模具应进行不同的表面处理以得到不同级别的表面硬度。以高强度钢板B170P1、DP590和DP780为对象，研究高强度钢板冲压成形时钢板强度与模具硬度的匹配问题。首先以钢板表面损伤Ry值为设计目标，以钢板硬度（即钢板强度）、模具硬度、零件冲压次数为变量因子，进行Box-Behnken实验设计。在实验研究的基础上，建立二阶响应面模型，最后通过模型重构建立钢板与模具硬度匹配窗口。利用此匹配窗口，可有效指导模具选材、以及模具寿命预测，抑制高强度钢板表面损伤发生，降低产品废品率。
（4）镀锌钢板表面损伤分析
热镀锌、热镀锌合金化和电镀锌是典型的镀锌工艺，不同性质的锌镀层与模具表面形成不同的摩擦副，在钢板冲压加工中产生不同类型和不同程度的表面损伤，因此对于不同类型镀锌钢板的冲压加工，应使用不同表面状态的模具以减轻板料表面损伤缺陷。首先研究模具硬度、模具粗糙度对不同种类镀锌钢板的影响规律，在此基础上分析三种镀锌工艺对钢板表面损伤类型的影响，提出抑制镀锌钢板表面损伤的技术措施。最后通过对镀锌钢板镀层硬度、表面形貌、化学成分等的测量和分析，揭示不同镀锌钢板表面损伤产生的机理。根据本章研究内容可以确定模具表面状态，进而减轻三种镀锌钢板冲压加工中的表面损伤缺陷。
通过以上研究工作，本文对高强度钢板和镀锌钢板在冲压加工中的表面损伤现象进行了全面和系统的分析。从钢板冲压成形中板料表面损伤特征、物理模拟方法、评价等方面都进行了较为深入的探讨，对模具因素、工艺条件、钢板种类对板料表面损伤的影响都进行了比较全面的研究，为高强度钢板和镀锌钢板在汽车制造中的进一步推广，奠定了坚实的基础。
The demands for lightweight security and corrosion-resistance in automotiveindustry have focused the attention of automotive manufacturers on the use of highstrength steels and galvanized steels. At the same time, the application of highstrength steels and galvanized steels presents many challenges in sheet metal forming.For high strength steels problems with surface damages are of major interest, sinceforming pressures are high, as well as blank holder forces. For galvanized steels,powdering, abscission and crack of coatings are popular in the forming processes.Surface damage is one of the major problems in the forming of high strength steelsand galvanized steels, which not only decreases the corrosion resistance and surfacequalities of products but also decrease the stability of the forming process. It canextend the use field and proportion of the high strength steels and galvanized steelsand shorten the time of new product design if the surface damages of high strengthsteels and galvanized steels are decreased.
Based on the comparison and evaluation of the surface damages of the highstrength steels and galvanized steels, sheet surface damage in sheet metal forming areinvestigated systemically. The experimental and evaluating methods on the surfacedamage in sheet metal forming are established through the analysis of thecharacteristics of sheet deformation, the friction between the blank and the tool. Andthen the effects of the forming tool and process parameters on sheet surface damageare investigated and the model of sheet surface damage in the forming of highstrength steels is established. Aimed at the forming process of different high strengthsteels, the hardness matching window of sheet material and forming tool is defined.At last the effects of tool hardness and surface roughness on surface damages of thegalvanized steels and the influence of galvanized process on surface damage areinvestigated. And the characteristics and mechanisms of surface damages in theforming of hot-dip galvanized, galvannealed and electro-galvanized steels are studied.To fulfill the above research objectives, the following four aspects of efforts areperformed:
(1) Experimental and evaluating system of sheet surface damages for the sheetmetal stamping
The frictional characteristics between the die and the sheet blank in sheet metalforming are different with the traditional contact friction between two solid due to theplastic deformation of sheet material and complexity of sheet deformation. Therefore,the contact characteristics between the die and the sheet blank in sheet metal formingare analysed firstly in this chapter and a complicated part that have typical sheetdeformations in stamping is designed to study the sheet surface damages in sheetmetal forming. To study the effects of the forming tools and sheet materials on sheetsurface damages, U-channel forming experiment with draw-bead is selected tosimulate sheet surface damage in the forming of sheet steels under tension-bending.Finally, based on the producing conditions in automobile industry, the experimentalproject is established and the parameter to evaluate sheet surface damage and themethod to measure the parameter are studied. This chapter is the foundation of theexperiments described in the followed chapters.
(2) The rules and numerical model of sheet surface damage for the forming ofhigh strength steel under tension-bending
The effects of tool materials Cr12MoV, Mo-Cr alloy cast iron, nodular iron andgray cast iron on sheet surface damages are studied using the high strength steelB170P1. It is demonstrated that Mo-Cr alloy cast iron is the best tool material amongthe investigated materials for sheet metal forming. Through the U-channel formingtests, the effects of tool hardness, tool surface roughness, blank holder force andlubrication on blank surface damage are investigated. It is indicated that sheet surfacedamages can be decreased through increasing tool hardness, surface roughness anddecreasing blank holder force. Based on the experimental data, the model for thesurface damage in the forming of high strength steels is established through non-linearcurve fitting. The reliability of the equation was validated. Using the results of thischapter, the technical measures can be established considering the effects of formingtools and process parameters on sheet surface damages and the sheet surface damageswill be decreased obviously.
(3) Hardness matching window of the blank and die aimed at surface damages ofhigh strength steels
Tool hardness is one of the important factors that influence sheet surface damage insheet metal forming and it also affects tool wear, tool life and the cost of tool manufacture. With increasing of sheet strength, heavy sheet surface damages and toolabrasion are happied. Thus, for the forming of the high strength steels with differentstrength, the forming tools should be heat treated with different mothods to getdifferent tool hardness. In this chapter, using the high strength steels B170P1, DP590and DP780the matching of sheet strength and tool hardness is researched. The effectsof tool hardness on different high strength steels are investigated based on theBox-Behnken test design and then the hardness matching window of sheet materialand forming tool is established. The selection of tool materials and prediction of toollife can be done through the matching window, and then the sheet surface damagesand part rejection rate can be decreased.
(4) Effects and mechanism of galvanized coatings on surface damage
Hot-dip galvanized, galvannealed and electro-galvanized process are the typicalgalvanized processes and the surface damages of the three types of galvanized steelsare different with each other. Firstly, the effects of tool hardness and tool surfaceroughness on surface damages of galvanized steels are investigated. And then theeffects of galvanized processes on the types of sheet surface damages in the formingof galvanized steels are studied and the methods of decreasing surface damages ofgalvanized steels are proposed. Finally, the mechanisms of sheet surface damages ofdifferent galvanized steels are investigated through the analyses of coating hardness,surface topography and chemical composition.
Through this research, the sheet surface damages in the forming of high strengthsteels and galvanized steels are studied comprehensively. The characteristics,simulating methods and evaluation of sheet surface damage in sheet metal forming areanalysised. The effects of the forming tool, process parameters and sheet materials onsheet surface damages are studied. The research will extend the usages of highstrength steels and galvanized steels in automobile industry.
本文在借鉴和吸收国内外先进研究成果的基础上，针对高强度钢板和镀锌钢板在冲压成形中的表面损伤现象进行了系统研究。首先根据板料冲压加工中的变形、摩擦等特点以及板料表面损伤的特征建立板料表面损伤物理模拟实验及评价系统；在此基础上研究模具和工艺等因素对高强度钢板表面损伤的影响规律，建立高强度钢板表面损伤演化模型；接着研究不同模具硬度条件下钢板强度对板料表面损伤的影响规律，建立可抑制表面损伤缺陷的钢板与模具硬度匹配窗口；最后研究镀锌钢板表面损伤规律以及镀锌工艺对镀锌板表面损伤类型的影响，揭示镀锌钢板表面损伤特点以及产生机理。本文的主要研究内容如下：
（1）针对钢板冲压加工特点的板料表面损伤物理模拟实验研究
由于车身覆盖件冲压成形中钢板的塑性变形行为以及变形模式的复杂性，使用传统摩擦实验装置不能模拟钢板与模具间的接触摩擦。首先分析车身覆盖件冲压成形中钢板与模具间的接触摩擦特点以及板料表面损伤特征，设计一具有多种板料变形模式的复杂零件来研究钢板冲压加工中的板料表面损伤。为进一步研究模具、工艺及板料因素对板料表面损伤的影响规律，设计带拉延筋的U形件来模拟钢板在拉伸-弯曲变形模式下的表面损伤现象。最后基于车身覆盖件生产现场工况，制定钢板表面损伤影响因素变化范围，设计板料表面损伤模拟实验方案，并研究板料表面损伤定量评价参数及其测量方法。
（2）高强度钢板表面损伤规律及其演化模型建立
以高强度钢板B170P1为研究对象，首先研究模具材料Cr12MoV、Mo-Cr合金铸铁、球墨铸铁和灰铸铁对钢板表面损伤的影响，结果表明，Mo-Cr合金铸铁是适合高强度钢板冲压成形的最优模具材料。接着使用不同硬度、粗糙度水平的Mo-Cr合金铸铁模具，研究模具和工艺条件等因素对钢板表面损伤的影响规律，得出可以通过提高模具硬度、模具表面粗糙度等级以及适当减小压边力等措施来减轻板料表面损伤缺陷。最后在物理模拟实验数据的基础上，建立高强度钢板表面损伤演化模型，并验证了模型的正确性。利用本部分的研究内容，可以综合考虑模具及工艺等因素来制定技术措施，进而抑制或减轻板料表面损伤缺陷。
（3）面向高强钢板表面损伤的板材与模具硬度匹配窗口建立
随着钢板强度水平的提高，钢板冲压成形需要更高的压边力，冲压加工中更容易引起板料表面损伤，而且由于钢板硬度的提高，模具磨损也更严重。因此，对于不同强度等级的高强度钢板冲压成形，模具应进行不同的表面处理以得到不同级别的表面硬度。以高强度钢板B170P1、DP590和DP780为对象，研究高强度钢板冲压成形时钢板强度与模具硬度的匹配问题。首先以钢板表面损伤Ry值为设计目标，以钢板硬度（即钢板强度）、模具硬度、零件冲压次数为变量因子，进行Box-Behnken实验设计。在实验研究的基础上，建立二阶响应面模型，最后通过模型重构建立钢板与模具硬度匹配窗口。利用此匹配窗口，可有效指导模具选材、以及模具寿命预测，抑制高强度钢板表面损伤发生，降低产品废品率。
（4）镀锌钢板表面损伤分析
热镀锌、热镀锌合金化和电镀锌是典型的镀锌工艺，不同性质的锌镀层与模具表面形成不同的摩擦副，在钢板冲压加工中产生不同类型和不同程度的表面损伤，因此对于不同类型镀锌钢板的冲压加工，应使用不同表面状态的模具以减轻板料表面损伤缺陷。首先研究模具硬度、模具粗糙度对不同种类镀锌钢板的影响规律，在此基础上分析三种镀锌工艺对钢板表面损伤类型的影响，提出抑制镀锌钢板表面损伤的技术措施。最后通过对镀锌钢板镀层硬度、表面形貌、化学成分等的测量和分析，揭示不同镀锌钢板表面损伤产生的机理。根据本章研究内容可以确定模具表面状态，进而减轻三种镀锌钢板冲压加工中的表面损伤缺陷。
通过以上研究工作，本文对高强度钢板和镀锌钢板在冲压加工中的表面损伤现象进行了全面和系统的分析。从钢板冲压成形中板料表面损伤特征、物理模拟方法、评价等方面都进行了较为深入的探讨，对模具因素、工艺条件、钢板种类对板料表面损伤的影响都进行了比较全面的研究，为高强度钢板和镀锌钢板在汽车制造中的进一步推广，奠定了坚实的基础。
The demands for lightweight security and corrosion-resistance in automotiveindustry have focused the attention of automotive manufacturers on the use of highstrength steels and galvanized steels. At the same time, the application of highstrength steels and galvanized steels presents many challenges in sheet metal forming.For high strength steels problems with surface damages are of major interest, sinceforming pressures are high, as well as blank holder forces. For galvanized steels,powdering, abscission and crack of coatings are popular in the forming processes.Surface damage is one of the major problems in the forming of high strength steelsand galvanized steels, which not only decreases the corrosion resistance and surfacequalities of products but also decrease the stability of the forming process. It canextend the use field and proportion of the high strength steels and galvanized steelsand shorten the time of new product design if the surface damages of high strengthsteels and galvanized steels are decreased.
Based on the comparison and evaluation of the surface damages of the highstrength steels and galvanized steels, sheet surface damage in sheet metal forming areinvestigated systemically. The experimental and evaluating methods on the surfacedamage in sheet metal forming are established through the analysis of thecharacteristics of sheet deformation, the friction between the blank and the tool. Andthen the effects of the forming tool and process parameters on sheet surface damageare investigated and the model of sheet surface damage in the forming of highstrength steels is established. Aimed at the forming process of different high strengthsteels, the hardness matching window of sheet material and forming tool is defined.At last the effects of tool hardness and surface roughness on surface damages of thegalvanized steels and the influence of galvanized process on surface damage areinvestigated. And the characteristics and mechanisms of surface damages in theforming of hot-dip galvanized, galvannealed and electro-galvanized steels are studied.To fulfill the above research objectives, the following four aspects of efforts areperformed:
(1) Experimental and evaluating system of sheet surface damages for the sheetmetal stamping
The frictional characteristics between the die and the sheet blank in sheet metalforming are different with the traditional contact friction between two solid due to theplastic deformation of sheet material and complexity of sheet deformation. Therefore,the contact characteristics between the die and the sheet blank in sheet metal formingare analysed firstly in this chapter and a complicated part that have typical sheetdeformations in stamping is designed to study the sheet surface damages in sheetmetal forming. To study the effects of the forming tools and sheet materials on sheetsurface damages, U-channel forming experiment with draw-bead is selected tosimulate sheet surface damage in the forming of sheet steels under tension-bending.Finally, based on the producing conditions in automobile industry, the experimentalproject is established and the parameter to evaluate sheet surface damage and themethod to measure the parameter are studied. This chapter is the foundation of theexperiments described in the followed chapters.
(2) The rules and numerical model of sheet surface damage for the forming ofhigh strength steel under tension-bending
The effects of tool materials Cr12MoV, Mo-Cr alloy cast iron, nodular iron andgray cast iron on sheet surface damages are studied using the high strength steelB170P1. It is demonstrated that Mo-Cr alloy cast iron is the best tool material amongthe investigated materials for sheet metal forming. Through the U-channel formingtests, the effects of tool hardness, tool surface roughness, blank holder force andlubrication on blank surface damage are investigated. It is indicated that sheet surfacedamages can be decreased through increasing tool hardness, surface roughness anddecreasing blank holder force. Based on the experimental data, the model for thesurface damage in the forming of high strength steels is established through non-linearcurve fitting. The reliability of the equation was validated. Using the results of thischapter, the technical measures can be established considering the effects of formingtools and process parameters on sheet surface damages and the sheet surface damageswill be decreased obviously.
(3) Hardness matching window of the blank and die aimed at surface damages ofhigh strength steels
Tool hardness is one of the important factors that influence sheet surface damage insheet metal forming and it also affects tool wear, tool life and the cost of tool manufacture. With increasing of sheet strength, heavy sheet surface damages and toolabrasion are happied. Thus, for the forming of the high strength steels with differentstrength, the forming tools should be heat treated with different mothods to getdifferent tool hardness. In this chapter, using the high strength steels B170P1, DP590and DP780the matching of sheet strength and tool hardness is researched. The effectsof tool hardness on different high strength steels are investigated based on theBox-Behnken test design and then the hardness matching window of sheet materialand forming tool is established. The selection of tool materials and prediction of toollife can be done through the matching window, and then the sheet surface damagesand part rejection rate can be decreased.
(4) Effects and mechanism of galvanized coatings on surface damage
Hot-dip galvanized, galvannealed and electro-galvanized process are the typicalgalvanized processes and the surface damages of the three types of galvanized steelsare different with each other. Firstly, the effects of tool hardness and tool surfaceroughness on surface damages of galvanized steels are investigated. And then theeffects of galvanized processes on the types of sheet surface damages in the formingof galvanized steels are studied and the methods of decreasing surface damages ofgalvanized steels are proposed. Finally, the mechanisms of sheet surface damages ofdifferent galvanized steels are investigated through the analyses of coating hardness,surface topography and chemical composition.
Through this research, the sheet surface damages in the forming of high strengthsteels and galvanized steels are studied comprehensively. The characteristics,simulating methods and evaluation of sheet surface damage in sheet metal forming areanalysised. The effects of the forming tool, process parameters and sheet materials onsheet surface damages are studied. The research will extend the usages of highstrength steels and galvanized steels in automobile industry.
引文
[1]张理扬,左良,李俊.冷轧和镀锌汽车板的发展.特殊钢.2004(6):1-6.
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