汽车门外板B柱冲压表面缺陷控制方法
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摘要
针对汽车外覆盖件在冲压过程中的表面缺陷现象,以某车型前门外板为对象,研究了门外板B柱表面缺陷的控制方法问题。首先介绍了表面缺陷产生的主要原因,然后从压料面造型、工艺补充面造型、拉延筋造型3个方面优化拉深冲压工艺,利用Autoform软件对工艺优化前后零件的表面缺陷程度进行预测比较;最后对B柱边口局部模面进行补偿,将边口曲面曲率半径减小至4000～8000 mm以内,并对理论与实际补偿模面的曲面质量进行检查,以确保补偿曲面质量。结果表明,均匀的拉深工艺面造型以及对B柱进行局部模面补偿可以有效地控制门外板B柱表面缺陷,为研究表面缺陷控制问题提供了一种参考思路。
According to the surface defect problem occurring in stamping automobile outer panel,the front outer door panel of a car was taken as the example,the control of surface defect in B pillar of automobile outer door panel was studied.Firstly,the main cause of the surface defect was introduced.Then the drawing stamping process was optimized from the following three aspects:binder surface geometry,drawing addendum geometry and drawbead type,and the part surface defects before and after optimization were predicted and compared by Autoform.At last,the partial die surface near B pillar boundary was compensated.The radius of curvature near the boundary was reduced in the ranges from 4000 to 8000 mm,the theoretic and practical compensated surfaces were checked to ensure the surface quality.The results show that the uniform drawing depth and addendum geometry,and partial surface compensation in B pillar can efficiently control the surface defect in B pillar of automobile outer door panel,which provides a new reference idea to the research on the surface defect control problem.
According to the surface defect problem occurring in stamping automobile outer panel,the front outer door panel of a car was taken as the example,the control of surface defect in B pillar of automobile outer door panel was studied.Firstly,the main cause of the surface defect was introduced.Then the drawing stamping process was optimized from the following three aspects:binder surface geometry,drawing addendum geometry and drawbead type,and the part surface defects before and after optimization were predicted and compared by Autoform.At last,the partial die surface near B pillar boundary was compensated.The radius of curvature near the boundary was reduced in the ranges from 4000 to 8000 mm,the theoretic and practical compensated surfaces were checked to ensure the surface quality.The results show that the uniform drawing depth and addendum geometry,and partial surface compensation in B pillar can efficiently control the surface defect in B pillar of automobile outer door panel,which provides a new reference idea to the research on the surface defect control problem.
引文
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[13]孙东继,贺亮,赵金龙.汽车覆盖件表面凹陷的CAE识别方法[J].模具工业,2014,40(5):22-24.SUN Dongji,HE Liang,ZHAO Jinlong.CAE identification method for automobile panel surface indentation[J].Die&Mould Industry,2014,40(5):22-24.
[14]倪啸枫,沈洪庆,李淑慧.车身外覆盖件面畸变缺陷影响因素[J].塑性工程学报,2013,20(3):48-54.NI Xiaofeng,SHEN Hongqing,LI Shuhui.Study on the influence factors for surface low of exterior auto-panels[J].Journal of Plasticity of Engineering,2013,20(3):48-54.
[2]倪啸枫,沈洪庆,李淑慧.车身外覆盖件面畸变缺陷模面补偿方法[J].机械工程学报,2013,49(5):123-128.NI Xiaofeng,SHEN Hongqing,LI Shuhui.Method of surface defects control by tool surface compensation for exterior auto-panels[J].Journal of Mechanical Enginerring,2013,49(5):123-128.
[3]孙振忠,杨玉英.柱面扁壳面畸变形成机理及控制[J].机械工程学报,2005,41(5):210-214.SUN Zhenzhong,YANG Yuying.Generating mechanism and controlling technique on surface deflection of culinder shallow shells[J].Journal of Mechanical Enginerring,2005,41(5):210-214.
[4]刘瑞同,林建平,田浩彬.轿车覆盖件表面瘪塘的分类及其特点[J].金属成形工艺,2004,22(2):52-54.LIU Ruitong,LIN Jianping,TIAN Haobin.The classification and characteristics of surface dent in automotive covering part[J].Metal Forming Technology,2004,22(2):52-54.
[5]付争春,马俊山,胡平,等.汽车外覆盖件表面凹陷与畸变的实验与仿真[J].塑性工程学报,2009,16(2):24-28.FU Zhengchun,MA Junshan,HU Ping,et al.Research on experiment and simulation of automobile panel surface low and distortion[J].Journal of Plasticity of Engineering,2009,16(2):24-28.
[6]李荣泳,陈海彬,陈盛贵,等.板料性能参数对覆盖件面畸变影响的研究[J].机电工程技术,2011,40(6):57-61.LI Rongyong,CHEN Haibin,CHEN Shenggui,et al.Study on effect of sheet metal properties on auto-body panel surface deflection[J].Mechanical and Electrical engineering Technology,2011,40(6):57-61.
[7]周驰,周旭辉,张赛军,等.车门成形后凹陷成因分析和应对措施[J].模具工业,2011,37(12):18-20.ZHOU Chi,ZHOU Xuhui,ZHANG Saijun,et al.Analysis on causes of partial depression after door shaping and countermeasures[J].Die&Mould Industry,2011,37(12):18-20.
[8]赵世超,万劲.冲压车门外板表面质量控制方法[J].模具制造,2014,(5):37-39.ZHAO Shichao,WAN Jin.Control method of surface quality for the automobile outer door plate[J].Die&Mould Manufacture,2014,(5):37-39.
[9]武永甫.汽车外覆盖件冲压表面畸变预测与模面补偿研究[J].锻压技术,2014,39(12):101-105.WU Yongfu.Research on prediction of stamping surface defects and die surface compensation for automobile exterior panel[J].Forging&Stamping Technology,2014,39(12):101-105.
[10]林策,彭艳,孙建亮,等.板形缺陷板料冲压变形及回弹仿真分析[J].锻压技术,2012,37(6):174-178.LIN Ce,PENG Yan,SUN Jianliang,et al.Stamping deformation and springback simulation analysis of sheet metal with shape defects[J].Forging&Stamping Technology,2012,37(6):174-178.
[11]李淑慧,沈洪庆,倪啸枫,等.车身覆盖件冲压成形面畸变缺陷形成机理研究[J].机械工程学报,2013,49(6):153-159.LI Shuhui,SHEN Hongqing,NI Xiaofeng,et al.Mechanism of surface low during the stamping process of automobile exterior panels[J].Journal of Mechanical Engineering,2013,49(6):153-159.
[12]孙振忠,杨玉英,赵立红.柱面扁壳面畸变的实验研究[J].材料科学与工艺,2005,13(4):372-374.SUN Zhenzhong,YANG Yuying,ZHAO Lihong.Experiment study on surface deflection of cylinder shallow shells[J].Material Science&Technology,2005,13(4):372-374.
[13]孙东继,贺亮,赵金龙.汽车覆盖件表面凹陷的CAE识别方法[J].模具工业,2014,40(5):22-24.SUN Dongji,HE Liang,ZHAO Jinlong.CAE identification method for automobile panel surface indentation[J].Die&Mould Industry,2014,40(5):22-24.
[14]倪啸枫,沈洪庆,李淑慧.车身外覆盖件面畸变缺陷影响因素[J].塑性工程学报,2013,20(3):48-54.NI Xiaofeng,SHEN Hongqing,LI Shuhui.Study on the influence factors for surface low of exterior auto-panels[J].Journal of Plasticity of Engineering,2013,20(3):48-54.