一种散热器上托底板成形工艺改进研究
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摘要
针对上托底板试产过程中出现的前后侧翼宽度不足、起皱、减薄等问题,根据散热器上托板零件形体存在盒形件成分的特点,调整了工艺内容,将"U形弯曲→W状成形"修改为"拉深→W状成形"。利用Dynaform软件对改进工艺从模具结构及压边力和摩擦条件等工艺参数方面进行了数值模拟分析。结果表明,压边力为200 k N,采用差异摩擦系数,即取凸模摩擦系数为0. 170、凹模和压边圈摩擦系数为0. 125,凹模拐角渐变半径范围由4t～6t增大至5t～8t (t为板料厚度)时,改善了呈面内弯曲状侧翼弯曲内侧的起皱和上端面凸圆角部分的减薄问题。在工艺参数已确定的条件下,对拉深深度h进行了探究,并确定h值为55 mm时,成形效果更好。改进后零件减薄率能控制在20%范围内,保证了零件的刚度。
Aiming at the problems such as insufficient width of front and rear flanks,wrinkling and thinning during the production process of uplifted bottom plate in trial,according to the characteristic that the radiator uplifted bottom plate body has a box-shaped part ingradient,the current process was optimized from ‘U-shaped bending→W-shaped forming'to ‘drawing→ W-shaped forming'. The optimized forming process was numerical simulated and analyzed by Dynaform software from the aspects of mold structure and parameters such as holder force and friction condition. The results show that the problems of wrinkling on the inner side of the inboard curved side flaps and thinning of the rounded corners of upper surface are improved when the blank holder force is 200 k N,the differential friction coefficient is selected that the punch is 0. 170,the die and the blank holder are 0. 125,and the gradient die corner radius increases from 4 t-6 t to 5 t-8 t( t is the thickness of plate). With the determined process parameters,the drawing depth h was explored,and it was confirmed that better forming result can be obtained when h = 55 mm. The thinning rate of parts can be controlled within 20% after improvement,which ensures the rigidity of parts.
Aiming at the problems such as insufficient width of front and rear flanks,wrinkling and thinning during the production process of uplifted bottom plate in trial,according to the characteristic that the radiator uplifted bottom plate body has a box-shaped part ingradient,the current process was optimized from ‘U-shaped bending→W-shaped forming'to ‘drawing→ W-shaped forming'. The optimized forming process was numerical simulated and analyzed by Dynaform software from the aspects of mold structure and parameters such as holder force and friction condition. The results show that the problems of wrinkling on the inner side of the inboard curved side flaps and thinning of the rounded corners of upper surface are improved when the blank holder force is 200 k N,the differential friction coefficient is selected that the punch is 0. 170,the die and the blank holder are 0. 125,and the gradient die corner radius increases from 4 t-6 t to 5 t-8 t( t is the thickness of plate). With the determined process parameters,the drawing depth h was explored,and it was confirmed that better forming result can be obtained when h = 55 mm. The thinning rate of parts can be controlled within 20% after improvement,which ensures the rigidity of parts.
引文
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[2]熊保玉,李文平.汽车底板支架冲压成形工艺CAE研究[J].锻压技术,2015,40(8):144-148.XIONG Baoyu,LI Wenping.CAE study on stamping process for car bottom bracket[J].Forging&Stamping Technology,2015,40(8):144-148.
[3]胡建华,覃天,苏广才.CN100汽车发动机油底壳一次拉深成形探索研究[J].装备制造技术,2012,(6):22-24.HU Jianhua,QIN Tian,SU Guangcai.Study on drawing of CN100automobile engine of oil pan[J].Equipment Manufacturing Technology,2012,(6):22-24.
[4]袁小江.支架钣金件成形受力分析与工艺模拟[J].锻压技术,2017,42(7):19-23.YUAN Xiaojiang.Stress analysis and process simulation of support stamping part in forming[J].Forging&Stamping Technology,2017,42(7):19-23.
[5]赵石岩,张有为,高杨,等.斜壁盒形件滚动拉深成形工艺的有限元分析[J].塑性工程学报,2017,24(5):38-43,67.ZHAO Shiyan,ZHANG Youwei,GAO Yang,et al.Finite element analysis of the rolling drawing process of inclined wall box[J].Journal of Plasticity Engineering,2017,24(5):38-43,67.
[6]王泓宇,李细锋,陈军.AA1100铝合金渐进成形的微观组织与力学性能分析[J].塑性工程学报,2018,25(6):180-188.WANG Hongyu,LI Xifeng,CHEN Jun.Analysis on microstructure and mechanical properties of AA1100 aluminum alloy in incremental sheet forming[J].Journal of Plasticity Engineering,2018,25(6):180-188.
[7]陈志珺,刘渝,蔡江,等.基于Dynaform的汽车前托架成形分析及参数优化[J].锻压技术,2017,42(6):174-179.CHEN Zhijun,LIU Yu,CAI Jiang,et al.Forming analysis and parameter optimization for automobile front bracket based on Dynaform[J].Forging&Stamping Technology,2017,42(6):174-179.
[8]苏春建,于涛.金属板材成形CAE分析及应用[M].北京:国防工业出版社,2011.SU Chunjian,YU Tao.CAE analysis and application of sheet metal forming[M].Beijing:National Defense Industry Press,2011.
[9]龚红英.板料成形性能及CAE分析[M].北京:机械工业出版社,2014.GONG Hongying.Sheet metal formability and cae analysis[M].Beijing:China Machine Press,2014.
[10]张如华,赵向阳,章跃荣.冲压工艺与模具设计[M].北京:清华大学出版社,2006.ZHANG Ruhua,ZHAO Xiangyang,ZHANG Yuerong.Stamping process and design of die[M].Beijing:Tsinghua University Press,2006.
[11]梁建农.不锈钢盒形件拉深成形的有限元仿真与优化[D].广州:华南理工大学,2013.LIANG Jiannong.Finite element simulation and optimization of stainless steel rectangular box drawing and forming[D].Guangzhou:South China University of Technology,2013.
[12]BRABIE G,CHIRTIA B,ALBUT A.Minimization of sheet thickness variation and other defects of mini drawn parts using a blank holder plate made from concentric rings[J].Precision Engineering,2015,42:311-320.
[13]MARUMO Y,SAIKI H,RUAN L.Effect of sheet thickness on deep drawing of metal foils[J].Achievements in Mechanical&Materials Engineering,2007,20:479-82.
[14]DEMERCI H I,YASAR M,DEMIRAY K.The theoretical and experimental investigation of blank holder forces plate effect in deep drawing process of Al 1050 material[J].Materials and Design,2008,29:526-532.
[15]NARANJE V,KUMAR S.A knowledge based system for automated design of deep drawing die for axisymmetric parts[J].Expert Systems with Applications,2014,41(4):1419-1431.
[16]LIN B T,KUO C C.Application of the fuzzy-based taguchi method for the structural design of drawing dies[J].The International Journal Advanced Manufacturing Technology,2011,55(1/4):83-93.
[17]谢晖,黄康,陈建新,等.双层不锈钢消声器壳体冲压工艺CAE分析与优化[J].塑性工程学报,2018,25(2):1-8.XIE Hui,HUANG Kang,CHEN Jianxin,et al.CAE simulation and optimization of double-layer stainless steel muffler shell stamping process[J].Journal of Plasticity Engineering,2018,25(2):1-8.
[18]王镇江,刘新东.基于Dynaform横梁外板的数值模拟及优化[J].机械研究与应用,2013,26(5):24-25,30.WANG Zhenjiang,LIU Xindong.Numerical simulation and optimization of beam outer plate based on Dynaform[J].Mechanical Research&Application,2013,26(5):24-25,30.
[19]李金燕,傅建,彭必友,等.方形盒制件圆角处拉深破裂的数值模拟[J].塑性工程学报,2006,13(6):34-38,47.LI Jinyan,FU Jian,PENG Biyou,et al.The numerical simulation of fillet crack during square box drawing[J].Journal of Plasticity Engineering,2006,13(6):34-38,47.