前中央通道延伸板起皱分析与优化
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摘要
以某车型前中央通道延伸板为研究对象,分析其冲压成形工艺,利用Autoform建立有限元模型,对其成形过程中可能出现的开裂、起皱、回弹等缺陷进行预测,分析产生缺陷的原因并给出相应的优化方案。结果表明,通过调节压边力至800k N、增加工艺补充造型和修改拉延筋系数至0. 3,成功地消除了起皱缺陷;通过回弹仿真预测,发现回弹值在可控范围之内。最后进行实冲试验验证,其试模结果与CAE预测结果基本保持一致,表明了前期有限元分析和优化方案的有效性。利用优化后的方案指导生产,保证了产品的成形质量。
For the extension plate in front central channel of a car,the stamping process was analyzed. Then,the defects such as cracking,wrinkling and springback etc. during the forming process were predicted by the FE model established with Autoform software,and the causes of the defects were analyzed and the corresponding optimization scheme was given. The results show that the wrinkle defects are successfully eliminated by adjusting the blank holder force to 800 k N,adding the process supplementary molding and modifying the drawbead coefficient to 0. 3. It is found that the springback value is within the controllable range through the simulation prediction of springback. Finally,the actual stamping test was carried out,and the test results are basically consistent with the predicted results,which indicates that the finite element analysis and optimization scheme in the early stage are effective,and the quality of product can be guaranteed by the optimized solution to guide production.
For the extension plate in front central channel of a car,the stamping process was analyzed. Then,the defects such as cracking,wrinkling and springback etc. during the forming process were predicted by the FE model established with Autoform software,and the causes of the defects were analyzed and the corresponding optimization scheme was given. The results show that the wrinkle defects are successfully eliminated by adjusting the blank holder force to 800 k N,adding the process supplementary molding and modifying the drawbead coefficient to 0. 3. It is found that the springback value is within the controllable range through the simulation prediction of springback. Finally,the actual stamping test was carried out,and the test results are basically consistent with the predicted results,which indicates that the finite element analysis and optimization scheme in the early stage are effective,and the quality of product can be guaranteed by the optimized solution to guide production.
引文
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[8]陈保全,陈炜,李国强,等.汽车轮侧内板冲压工艺仿真与试验[J].锻压技术,2017,42(12):26-30.Chen B Q,Chen W,Li G Q,et al. Simulation and experiment ofautomobile wheel side inner plate in stamping process[J]. Forging&Stamping Technology,2017,42(12):26-30.
[9]段向敏,代荣.汽车覆盖件拉延成形过程分析[J].机械设计与制造,2013,(10):239-241.Dai X M,Dai R. The analysis of sheet metal forming process forautomotive cover[J]. Machinery Design&Manufacture,2013,(10):239-241.
[10]刘细芬,黄华艳.基于Autoform的汽车覆盖件冲压成形仿真技术研究[J].中国农机化,2010,54(3):87-90.Liu X F,Huang H Y. Research on simulation technology of auto-mobile panel stamping based on autoform[J]. Chinese Agricultur-al Mechanization,2010,54(3):87-90.
[11]吴善冬,周杰,李崇,等.汽车前纵梁内板拉延成形数值模拟及工艺参数优化[J].金属铸锻焊技术,2012,41(11):106-108.Wu S D,Zhou J,Li C,et al. Numerical simulation and parameteroptimization of front-carling inner plate[J]. Casting·Forging·Welding,2012,41(11):106-108.
[12]傅旻,孔垂有,张勇,等.汽车覆盖件成形中拉延筋的设计与数值模拟[J].机械设计与制造,2014,(2):239-242.Fu M,Kong C Y,Zhang Y,et al. Drawbead design and simula-tion of automobile panel forming[J]. Machinery Design&Manu-facture,2014,(2):239-242.
[2]张琪.乘用车地板通道零件回弹及起皱特性分析[J].锻压技术,2015,40(6):34-38.Zhang Q. Analysis on springback and wrinkle of car floor channelpart[J]. Forging&Stamping Technology,2015,40(6):34-38.
[3]林楷,尤彬波,苏丹,等.汽车后门内板转角起皱成因分析及对策[J].锻压技术,2017,42(6):43-50.Lin K,You B B,Su D,et al. Reason analysis and solutions ofwrinkles at corners of automobile rear door inner panel[J]. Forg-ing&Stamping Technology,2017,42(6):43-50.
[4]张凌云,孟伟琪,范作鹏.飞机凸翻边框肋零件橡皮成形起皱控制方法研究[J].塑性工程学报,2017,24(3):25-30.Zhang L Y,Meng W Q,Fan Z P. Control method of wrinkling inrubber forming of aircraft flange bending parts[J]. Journal ofPlasticity Engineering,2017,24(3):25-30.
[5]王成勇,戴程,安自仁,等.基于型面台阶法和工艺凹包法的车门内板局部起皱控制研究[J].塑性工程学报,2017,24(6):14-18.Wang C Y,Dai C,An Z R,et al. Research on local wrinkles ofinner door panel based on die surface steps method and processconvex hull method[J]. Journal of Plasticity Engineering,2017,24(6):14-18.
[6]李骁,郑松林,张振华,等.汽车门内板冲压成形起皱研究[J].热加工工艺,2014,43(7):154-158.Li X,Zheng S L,Zhang Z H,et al. Wrinkling research on autoinner door in sheet metal stamping forming[J]. Hot WorkingTechnology,2014,43(7):154-158.
[7]胡平,杜上锴.汽车覆盖件模具设计[M].北京:机械工业出版社,2011.Hu P,Du S K. Automobile Panel Die Design[M]. Beijing:China Machine Press,2011.
[8]陈保全,陈炜,李国强,等.汽车轮侧内板冲压工艺仿真与试验[J].锻压技术,2017,42(12):26-30.Chen B Q,Chen W,Li G Q,et al. Simulation and experiment ofautomobile wheel side inner plate in stamping process[J]. Forging&Stamping Technology,2017,42(12):26-30.
[9]段向敏,代荣.汽车覆盖件拉延成形过程分析[J].机械设计与制造,2013,(10):239-241.Dai X M,Dai R. The analysis of sheet metal forming process forautomotive cover[J]. Machinery Design&Manufacture,2013,(10):239-241.
[10]刘细芬,黄华艳.基于Autoform的汽车覆盖件冲压成形仿真技术研究[J].中国农机化,2010,54(3):87-90.Liu X F,Huang H Y. Research on simulation technology of auto-mobile panel stamping based on autoform[J]. Chinese Agricultur-al Mechanization,2010,54(3):87-90.
[11]吴善冬,周杰,李崇,等.汽车前纵梁内板拉延成形数值模拟及工艺参数优化[J].金属铸锻焊技术,2012,41(11):106-108.Wu S D,Zhou J,Li C,et al. Numerical simulation and parameteroptimization of front-carling inner plate[J]. Casting·Forging·Welding,2012,41(11):106-108.
[12]傅旻,孔垂有,张勇,等.汽车覆盖件成形中拉延筋的设计与数值模拟[J].机械设计与制造,2014,(2):239-242.Fu M,Kong C Y,Zhang Y,et al. Drawbead design and simula-tion of automobile panel forming[J]. Machinery Design&Manu-facture,2014,(2):239-242.