基于Dynaform和正交试验的轿车加强梁冲压工艺参数优化
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摘要
起皱、开裂和回弹是汽车覆盖件冲压成形时产生的主要质量问题,直接影响零件表面、尺寸和形状精度。以加强梁为例,利用Dynaform软件对冲压成形过程和回弹进行仿真模拟,采用正交试验和极差分析法,以最小厚度、最大回弹量、开裂和起皱为评价考察指标,研究了压边力、冲压速度、摩擦系数和凸凹模间隙对厚度和回弹的影响规律,优化冲压工艺参数和模具形面。将模拟分析得到的最小厚度值和最大回弹量与实际零件对比,验证了优化方案的合理性与模拟结果的准确性。有效地将零件厚度控制在0. 85～1. 15 mm之间,回弹控制在1. 1 mm以内,减少了修模次数和缩短了生产周期。
Wrinkling,cracking and springback are the main quality problems of stamping for automobile panel,which directly affect the surface,size and shape accuracy of parts. For the reinforced beam,the stamping process and springback were simulated by software Dynaform,and the influences of blank holder force,stamping speed,friction coefficient and clearance between punch and die on the thickness and the springback were studied by the orthogonal test and the range analysis as well as the evaluate indexes of the minimum thickness,the maximum springback,cracking and wrinkling,and the stamping process parameters and mold profile were optimized. By comparing the minimum thickness and the maximum springback of simulation analysis with the actual parts,the rationality of the optimization scheme and the accuracy of the simulation results were verified. The thickness of parts is effectively controlled between 0. 85-1. 15 mm,and the springback is controlled within 1. 1 mm,which reduces the number of die repair and the production cycle.
Wrinkling,cracking and springback are the main quality problems of stamping for automobile panel,which directly affect the surface,size and shape accuracy of parts. For the reinforced beam,the stamping process and springback were simulated by software Dynaform,and the influences of blank holder force,stamping speed,friction coefficient and clearance between punch and die on the thickness and the springback were studied by the orthogonal test and the range analysis as well as the evaluate indexes of the minimum thickness,the maximum springback,cracking and wrinkling,and the stamping process parameters and mold profile were optimized. By comparing the minimum thickness and the maximum springback of simulation analysis with the actual parts,the rationality of the optimization scheme and the accuracy of the simulation results were verified. The thickness of parts is effectively controlled between 0. 85-1. 15 mm,and the springback is controlled within 1. 1 mm,which reduces the number of die repair and the production cycle.
引文
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[8]周煊,吴先洋,张海英,等.基于正交试验法的齿类温锻件冲孔工艺优化[J].锻压技术,2017,42(10):19-25.Zhou X,Wu X Y,Zhang H Y,et al. Optimization on piercingprocess of warm forging gear parts based on orthogonal experiment[J]. Forging&Stamping Technology,2017,42(10):19-25.
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[10]谢晖,赵笠程,王杭燕,等.基于正交试验的不锈钢冲压模具磨损分析及优化[J].锻压技术,2017,42(10):132-137.Xie H,Zhao L C,Wang H Y,et al. Wear analysis and optimiza-tion on stainless steel stamping die based on orthogonal test[J].Forging&Stamping Technology,2017,42(10):132-137.
[11]鲜小红.基于Dynaform的印涂铝盖冲压拉深摩擦条件的数字化设计技术[J].锻压技术,2017,42(3):170-174.Xian X H. Digtalized design technology of drawing die clearancefor printed and coated aluminum covers based on Dynaform[J].Forging&Stamping Technology,2017,42(3):170-174.
[12]黄伟,李梦群,杨亚威.基于Dynaform的V形件弯曲回弹数值分析[J].锻压技术,2014,42(7):118-121.Huang W,Li Y Q,Yang Y W. Numerical analysis of springbackfor V-shaped pieces based on Dynaform[J]. Forging&Stamping Technology,2014,42(7):118-121.
[2]胡心平,苏合新,王言德.基于Dynaform的汽车前防撞梁支撑板的拉延模具设计[J].锻压技术,2017,42(9):118-122.Hu X P,Su H X,Wang Y D. Design on drawing die of automotivefront anti-collision beam support plate based on Dynaform[J].Forging&Stamping Technology,2017,42(9):118-122.
[3]陈继涛,宋海燕,朱永强.基于Dynaform的汽车发动机盖内板成形分析[J].锻压技术,2017,42(1):19-22.Chen J T,Song H Y,Zhu Y Q. Analysis on drawing process ofautomotive engine hood inner panel based on Dynaform[J].Forging&Stamping Technology,2017,42(1):19-22.
[4]李东君.基于Dynaform的某汽车外板件拉延分析与模具设计[J].锻压技术,2016,41(4):151-156.Li D J. Drawing analysis and die design of an automobile outerpanel based on Dynaform[J]. Forging&Stamping Technology,2016,41(4):151-156.
[5]段磊,蔡玉俊,莫国强,等.汽车覆盖件成形回弹仿真及模面优化研究[J].锻压技术,2017,42(2):34-38.Duan L,Cai Y J,Mo G Q,et al. Research on springback simula-tion and die surface optimization of automotive panel formingprocess[J]. Forging&Stamping Technology,2017,42(2):34-38.
[6]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):118-121,127.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):118-121,127.
[7]谢晖,赵笠程,王杭燕,等.基于正交试验的不锈钢冲压模具磨损分析及优化[J].锻压技术,2017,42(10):132-137.Xie H,Zhao L C,Wang H Y,et al. Wear analysis and optimiza-tion on stainless steel stamping die based on orthogonal test[J].Forging&Stamping Technology,2017,42(10):132-137.
[8]周煊,吴先洋,张海英,等.基于正交试验法的齿类温锻件冲孔工艺优化[J].锻压技术,2017,42(10):19-25.Zhou X,Wu X Y,Zhang H Y,et al. Optimization on piercingprocess of warm forging gear parts based on orthogonal experiment[J]. Forging&Stamping Technology,2017,42(10):19-25.
[9]王明伟.高莹莹.基于正交试验的高强钢汽车加强板冲压成形回弹分析[J]塑性工程学报,2015,22(5):45-51.Wang M W,Gao Y Y. Springback analysis on stamping of highstrength steel automobile reinforcing plate based on the orthogonaltest[J] Journal of Plasticity Engineering,2015,22(5):45-51.
[10]谢晖,赵笠程,王杭燕,等.基于正交试验的不锈钢冲压模具磨损分析及优化[J].锻压技术,2017,42(10):132-137.Xie H,Zhao L C,Wang H Y,et al. Wear analysis and optimiza-tion on stainless steel stamping die based on orthogonal test[J].Forging&Stamping Technology,2017,42(10):132-137.
[11]鲜小红.基于Dynaform的印涂铝盖冲压拉深摩擦条件的数字化设计技术[J].锻压技术,2017,42(3):170-174.Xian X H. Digtalized design technology of drawing die clearancefor printed and coated aluminum covers based on Dynaform[J].Forging&Stamping Technology,2017,42(3):170-174.
[12]黄伟,李梦群,杨亚威.基于Dynaform的V形件弯曲回弹数值分析[J].锻压技术,2014,42(7):118-121.Huang W,Li Y Q,Yang Y W. Numerical analysis of springbackfor V-shaped pieces based on Dynaform[J]. Forging&Stamping Technology,2014,42(7):118-121.