汽车后地板上横梁冲压工艺优化
|
摘要
某汽车后地板上横梁在拉延后,出现了严重的起皱缺陷。针对该问题,首先使用Auto Form软件模拟其拉延工序,分析起皱原因。由于拉延过程中板料中间的材料没有被充分拉延,导致在产品台阶圆角与侧壁交界处因剪应力造成起皱。其次,利用Auto Form软件对冲压工艺进行了优化。仿真实验结果表明,通过增大台阶面的过渡圆弧半径R可以减少起皱,当R值过大时,在后序翻边时会导致台阶边缘有开裂风险,当R为400 mm时,产品成形较好。最后,通过冲压试验验证该优化方案的有效性,起皱问题得到了有效控制,从而减少了模具开发成本,缩短了生产周期,保证了该产品按期交货。
For the problem of serious wrinkle after drawing of automobile rear floor upper beam,firstly,the drawing process was simulated by software Auto Form,and the cause of wrinkling was analyzed that during the drawing process,the material in the middle of sheet was not fully drawn,and wrinkles were formed at step fillet and sidewall junction zone of product due to shear stress. Next,the process optimization was conducted by software Auto Form. The simulation results show that the wrinkle can be reduced by increasing the radius R of transitional arc in the step surface. However,the edge of step produces a risk of cracking if the R is too large during the subsequent flanging process,and the product is formed well when R is 400 mm. Finally,the effectiveness of the optimization plan was verified through the actual stamping test,and the wrinkle problem is effectively controlled to reduce die costs,shorten production cycles and ensure that the product is delivered on time.
For the problem of serious wrinkle after drawing of automobile rear floor upper beam,firstly,the drawing process was simulated by software Auto Form,and the cause of wrinkling was analyzed that during the drawing process,the material in the middle of sheet was not fully drawn,and wrinkles were formed at step fillet and sidewall junction zone of product due to shear stress. Next,the process optimization was conducted by software Auto Form. The simulation results show that the wrinkle can be reduced by increasing the radius R of transitional arc in the step surface. However,the edge of step produces a risk of cracking if the R is too large during the subsequent flanging process,and the product is formed well when R is 400 mm. Finally,the effectiveness of the optimization plan was verified through the actual stamping test,and the wrinkle problem is effectively controlled to reduce die costs,shorten production cycles and ensure that the product is delivered on time.
引文
[1]陈炜,高霖,杨继昌,等.车身覆盖件模具数字化制造技术[J].中国机械工程,2004,15(24):23-26.Chen W,Gao L,Yang J C,et al. Digital manufacturing technolo-gy for auto panel drawing dies[J]. China Mechanical Engineer-ing,2004,15(24):23-26.
[2]陈炜,李新城,雷玉成,等.汽车覆盖件模具设计方法研究[J].航空制造技术,2005,(8):70-73.Chen W,Li X C,Lei Y C,et al. Research on design methods forautomobile panel dies[J]. Aeronautical Manufacturing Technolo-gy,2005,(8):70-73.
[3]李文平.汽车顶盖前横梁拉延成形工艺数值模拟分析[J].塑性工程学报,2017,24(2):118-121.Li W P. Numerical simulation analysis on drawing forming processof front cross member of automobile top cover[J]. Journal of Plas-ticity Engineering,2017,24(2):118-121.
[4]耿佩,崔玉琦,李军超.板材渐进成形破裂分析与数值模拟[J].锻压装备与制造技术,2017,52(3):79-82.Geng P,Cui Y Q,Li J C,et al. Analysis and numerical simulation ofprogressive forming fracture of sheet metal[J]. China MetalformingEquipment&Manufacturing Technology,2017,52(3):79-82.
[5]陈东辉,张建.基于CAE的QP980超高强钢零件冲压开裂及回弹控制[J].锻压技术,2018,43(5):177-183.Chen D H,Zhang J. Crack and springback control of ultra highstrength steel QP980 parts based on CAE[J]. Forging&StampingTechnology,2018,43(5):177-183.
[6]关来德.汽车侧围外板A柱拐角起皱的分析及解决方案[J].锻压技术,2017,42(4):50-54.Guan L D. Analysis and solution on corner wrinkling of side panelA column for automobile[J]. Forging&Stamping Technology,2017,42(4):50-54.
[7]刘辉,江莉,何欢欢.某汽车发动机罩内板冲压成形数值模拟及试验[J].锻压技术,2017,42(2):56-59.Liu H,Jiang L,He H H. Numerical simulation and experimenton stamping process for automobile hood inner panel[J]. Forging&Stamping Technology,2017,42(2):56-59.
[8]崔令江.汽车覆盖件冲压成形技术[M].北京:机械工业出版社,2003.Cui L J. Automobile Panel Stamping Technology[M]. Beijing:China Machine Press,2003.
[9]陈炜.冲压工艺与模具设计[M].北京:科学出版社,2015.Chen W. Stamping Process and Die Design[M]. Beijing:Sci-ence Press,2015.
[10]梁炳文.板金成形性能[M].北京:机械工业出版社,1999.Liang B W. Sheet Metal Forming Performance[M]. Beijing:China Machine Press,1999.
[11]姜奎华.冲压工艺与模具设计[M].北京:机械工业出版社,1999.Jiang Q H. Stamping Process and Die Design[M]. Beijing:Chi-na Machine Press,1999.
[12]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.
[2]陈炜,李新城,雷玉成,等.汽车覆盖件模具设计方法研究[J].航空制造技术,2005,(8):70-73.Chen W,Li X C,Lei Y C,et al. Research on design methods forautomobile panel dies[J]. Aeronautical Manufacturing Technolo-gy,2005,(8):70-73.
[3]李文平.汽车顶盖前横梁拉延成形工艺数值模拟分析[J].塑性工程学报,2017,24(2):118-121.Li W P. Numerical simulation analysis on drawing forming processof front cross member of automobile top cover[J]. Journal of Plas-ticity Engineering,2017,24(2):118-121.
[4]耿佩,崔玉琦,李军超.板材渐进成形破裂分析与数值模拟[J].锻压装备与制造技术,2017,52(3):79-82.Geng P,Cui Y Q,Li J C,et al. Analysis and numerical simulation ofprogressive forming fracture of sheet metal[J]. China MetalformingEquipment&Manufacturing Technology,2017,52(3):79-82.
[5]陈东辉,张建.基于CAE的QP980超高强钢零件冲压开裂及回弹控制[J].锻压技术,2018,43(5):177-183.Chen D H,Zhang J. Crack and springback control of ultra highstrength steel QP980 parts based on CAE[J]. Forging&StampingTechnology,2018,43(5):177-183.
[6]关来德.汽车侧围外板A柱拐角起皱的分析及解决方案[J].锻压技术,2017,42(4):50-54.Guan L D. Analysis and solution on corner wrinkling of side panelA column for automobile[J]. Forging&Stamping Technology,2017,42(4):50-54.
[7]刘辉,江莉,何欢欢.某汽车发动机罩内板冲压成形数值模拟及试验[J].锻压技术,2017,42(2):56-59.Liu H,Jiang L,He H H. Numerical simulation and experimenton stamping process for automobile hood inner panel[J]. Forging&Stamping Technology,2017,42(2):56-59.
[8]崔令江.汽车覆盖件冲压成形技术[M].北京:机械工业出版社,2003.Cui L J. Automobile Panel Stamping Technology[M]. Beijing:China Machine Press,2003.
[9]陈炜.冲压工艺与模具设计[M].北京:科学出版社,2015.Chen W. Stamping Process and Die Design[M]. Beijing:Sci-ence Press,2015.
[10]梁炳文.板金成形性能[M].北京:机械工业出版社,1999.Liang B W. Sheet Metal Forming Performance[M]. Beijing:China Machine Press,1999.
[11]姜奎华.冲压工艺与模具设计[M].北京:机械工业出版社,1999.Jiang Q H. Stamping Process and Die Design[M]. Beijing:Chi-na Machine Press,1999.
[12]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.