管状变截面汽车扭力梁内高压成形工艺
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摘要
目的研究管状变截面汽车扭力梁内高压成形过程及其成形质量的关键影响因素。方法采用数值模拟和试验相结合的方法,重点研究了预成形件形状、内压力通入时机和初始压力值对扭力梁内高压成形的影响。结果预成形件宽度过大或上模圆角处管坯壁厚过薄,将造成后续内高压合模过程中出现咬边或整形阶段发生破裂等缺陷;在内高压成形合模过程中通入适当内压,可有效避免扭力梁件出现圆弧过渡面塌陷、上下模圆角过度减薄等缺陷。结论当预成形模具V面下模引导角а介于60°~70°之间、T面下模引导角β介于65°~75°之间时,可以取得较理想的预成形效果;合模过程中即通入32 MPa内压,此时所得扭力梁实体件外观无明显缺陷,成形精度较高。
The paper aims to study key influencing factors of high-pressure forming process and forming quality of tubular cross-section automobile torsion beam. A numerical simulation and experiment was combined to study influences of preform shape, timing of initial pressure and initial pressure on high-pressure beam forming of torsion beam. If the width of the preform is too large or the wall thickness of the tube is too thin, defects such as undercut or plastic deformation would occur during the subsequent high-pressure clamping. Proper inner pressure in the die assembly of inner high-pressure forming could effectively avoid torsion beam member arc transition surface collapse, the upper and lower mold fillet excessive thinning and other defects. When the die angle α was between 60?~70? and the guide angle β of the die on the T surface was between 65°~75°, the ideal preforming effect could be obtained. If 32 MPa of inner pressure is supplied in die assembly, the torsion beam entity at this time has no apparent appearance of physical defects, forming a higher precision.
The paper aims to study key influencing factors of high-pressure forming process and forming quality of tubular cross-section automobile torsion beam. A numerical simulation and experiment was combined to study influences of preform shape, timing of initial pressure and initial pressure on high-pressure beam forming of torsion beam. If the width of the preform is too large or the wall thickness of the tube is too thin, defects such as undercut or plastic deformation would occur during the subsequent high-pressure clamping. Proper inner pressure in the die assembly of inner high-pressure forming could effectively avoid torsion beam member arc transition surface collapse, the upper and lower mold fillet excessive thinning and other defects. When the die angle α was between 60?~70? and the guide angle β of the die on the T surface was between 65°~75°, the ideal preforming effect could be obtained. If 32 MPa of inner pressure is supplied in die assembly, the torsion beam entity at this time has no apparent appearance of physical defects, forming a higher precision.
引文
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[2]苑世剑,韩聪,王小松,等.空心变截面构件内高压成形工艺与装备[J].机械工程学报,2012,48(18):21—27.YUAN Shi-jian,HAN Cong,WANG Xiao-song,et al.Hydroforming Processes and Equipments of Hollow Structures with Various Sections[J].Journal of Mechanical Engineering,2012,48(18):21—27.
[3]王锡兵,常嘉茂.汽车扭矩梁式悬架设计与仿真计算[J].农业装备与车辆工程,2008(7):29—31.WANG Xi-bing,CHANG Jia-mao.Design and Simulation Calculation of Twist Beam Suspension of Car[J].Agricultural Equipment&Vehicle Engineering,2008(7):29—31.
[4]KOSSMEIER Heinz,KOTHENBIIRGER Meinolf,CHRISTOPHLIEMKE Wigbert,et al.Transverse Beam and Method of Manufacturing a Transverse beam[J].US Patent,2000(4):11—14.
[5]曾小利,孙俊文,毛显红,等.某型轿车后扭力梁结构轻量化设计[C].2012重庆汽车工程学会年会论文集,重庆,2012.ZENG Xiao-li,SUN Jun-wen,MAO Xian-hong,et al.Lightweight Design of the Rear Torsion Beam of a Certain Type of Car[C].2012 Chongqing Automotive Engineering Society Annual Conference Papers,Chongqing,2012.
[6]LEE D C,YANG C H.An Analytical Approach for Design and Performance Evaluation of Torsion Beam Rear Suspension[J].Finite Elements in Analysis and Design,2013,63:98—106.
[7]张伟伟,韩聪,苑世剑,等.加载路径对扭力梁内高压成形壁厚分布和精度的影响[J].材料科学与工艺,2012,20(4):1—6.ZHANG Wei-wei,HAN Cong,YUAN Shi-jian,et al.Effect of Loading Paths on Thickness Distribution and Precision of a Hydroformed Torsion Beam[J].Materials Science and Technology,2012,20(4):1—6.
[8]周林.异形截面空心结构件内高压成形工艺研究[D].合肥:合肥工业大学,2008.ZHOU Lin.Research on Hydroforming of Profiled Crosssection Hollow Component[D].Hefei:Hefei University,2008.
[9]陈仙风,陈智勇,苏海波,等.不同成形工艺对扭力梁使用性能的影响研究[J].锻压技术,2014,39(3):112—116.CHEN Xian-feng,CHEN Zhi-yong,SU Hai-bo,et al.Study on the Effects of Different Forming Processes on the Performance of Torsion Beam[J].Forging&Stamping Technology,2014,39(3):112—116.
[10]苑世剑,王小松.内高压成形技术研究与应用新进展[J].塑性工程学报,2008,15(2):22—30.YUAN Shi-jian,WANG Xiao-song.Developments in Researches and Applications of Tube Hydroforming[J].Journal of Plasticity Engineering,2008,15(2):22—30.
[11]YOON S J,PARK J K,LEE M J,et al.Deformation During Hot Stamping Process of Tubular Beam[C].Proceedings of the 5th International Conference on Tube Hydroforming,Noboribetsu,Ken-ichi Manabe,2011:112—115.
[12]SCHNEIDER K,CHOI H,OH J,et al.High Strength Hydroformedautomotive Part Developed by POSCO[C].Hydroforming of Sheet-tubes and Profiles,Fellbach Mathias Liewald,2008:61—76.