基于CAE和灰色关联的汽车前门外板冲压成形工艺参数多目标优化
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摘要
以某车型前门外板为例,根据Auto Form初步数值模拟结果,将成形最大减薄率和修边后最大回弹量作为优化目标,以拉延R角半径、拉延筋阻力、摩擦系数、压边力、冲压速度为自变量,设计5因素4水平的正交试验。采用灰色关联分析法,对正交试验数据进行处理,计算各工艺参数对目标函数的关联系数和关联度,得到多目标优化的最优工艺参数组合:拉延R角半径为27 mm、拉延筋阻力为175 N·mm~(-1)、摩擦系数为0.13、压边力为1450 k N、冲压速度为2500 m·s~(-1)。使用优化过后的成形工艺参数在Auto Form中进行再次模拟,结果显示成形最大减薄率和修边后最大回弹量都得到合理控制。将优化后的工艺参数用于指导工艺设计和模面回弹补偿,然后进行模具结构设计、制造和试模,实际结果表明,前门外板冲压成形质量合格。
For automotive front door outer panel,according to preliminary numerical simulation results of Auto Form,taking the maximum thinning and the maximum springback after trimming as the optimization objectives,and taking the drawing circle radius R,drawbead resistance,friction coefficient,blank holder force and stamping speed as the independent variables,the orthogonal test of five factors and four levels was designed. Then,the data of orthogonal test were processed by grey relational analysis method,and the correlation coefficient and correlation degree of each process parameter to the objective function were calculated. Therefore,the optimal combination of process parameters for multi-objective optimization was obtained with the drawing circle radius of 27 mm,drawbead resistance of 175 N·mm~(-1),friction coefficient of 0. 13,blank holder force of 1450 k N and stamping speed of 2500 m·s~(-1). Furthermore,the forming process was simulated again by Auto Form with optimized process parameters. The results show that the maximum thinning and the maximum springback after trimming are reasonably controlled,and the die is designed,manufactured and tested by the optimized process parameters to guide the process design and springback compensation. Thus,the actual results show that the stamping quality of the front door outer panel is qualified.
For automotive front door outer panel,according to preliminary numerical simulation results of Auto Form,taking the maximum thinning and the maximum springback after trimming as the optimization objectives,and taking the drawing circle radius R,drawbead resistance,friction coefficient,blank holder force and stamping speed as the independent variables,the orthogonal test of five factors and four levels was designed. Then,the data of orthogonal test were processed by grey relational analysis method,and the correlation coefficient and correlation degree of each process parameter to the objective function were calculated. Therefore,the optimal combination of process parameters for multi-objective optimization was obtained with the drawing circle radius of 27 mm,drawbead resistance of 175 N·mm~(-1),friction coefficient of 0. 13,blank holder force of 1450 k N and stamping speed of 2500 m·s~(-1). Furthermore,the forming process was simulated again by Auto Form with optimized process parameters. The results show that the maximum thinning and the maximum springback after trimming are reasonably controlled,and the die is designed,manufactured and tested by the optimized process parameters to guide the process design and springback compensation. Thus,the actual results show that the stamping quality of the front door outer panel is qualified.
引文
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[2]李雪,程迎潮,刘罡,等.轿车侧围外板冲压成形分析[J].锻压技术,2011,36(3):27-32.Li X,Cheng Y C,Liu G,et al.Optimization on drawing process parameters for pick-up tailgate outer panel based on gray relational analysis[J].Forging&Stamping Technology,2011,36(3):27-32.
[3]赵茂俞,薛克敏,李萍.多目标质量的覆盖件成形工艺参数优化[J].机械工程学报,2009,45(8):276-282.Zhao M Y,Xue K M,Li P.Auto panel forming process parameters optimization of multi-objective quality[J].Journal of Mechanical Engineering,2009,45(8):276-282.
[4]Zhang J,Ruan G M.Optimization of stamping process for high strength steel alloy component using a multi-objective genetic algorithm automotive[J].Journal of Plasticity Engineering,2015,22(4):67-73.
[5]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 optimization on stainless steel stamping die based on orthogonal test[J].Forging&Stamping Technology,2017,42(10):132-137.
[6]田植诚,王成勇,李伟,等.基于灰色关联理论的汽车前纵梁塑性成形工艺再设计[J].锻压技术,2014,39(1):46-51.Tian Z C,Wang C Y,Li W,et al.Redesign of plastic forming process for automotive fore-carling based on gray relational analysis optimization scheme[J].Forging&Stamping Technology,2014,39(1):46-51.
[7]孔炎,薛克敏,李萍,等.基于正交试验和灰色系统理论的高强钢厚板折弯优化成形模拟及实验[J].锻压技术,2014,39(5):11-14.Kong Y,Xue K M,Li P,et al.Optimized simulation and experiment on high-strength thick steel plate bending based on orthogonal test and grey system theory[J].Forging&Stamping Technology,2014,39(5):11-14.
[8]Zuo W,E J Q,Liu X,et al.Orthogonal experimental design and fuzzy grey relational analysis for emitter efficiency of the micro-cylindrical combustor with a step[J].Applied Thermal Engineering,2016,103:945-951.