基于数值模拟分析异形工艺孔在汽车门内板塑性成形过程中的应用研究
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摘要
汽车后背门内板结构起伏大,塑性成形过程中板料的应力应变场复杂。结合板料开设工艺孔附近区域应力状态的理论分析,运用局部应力释放的方法,在产品四角和中间结构突变区域进行材料切除和开孔,改善了材料流动不均匀,缓解了局部应力集中的缺陷。利用有限元建模进行了多方案对比模拟分析,并与现场试模进行相互验证,重点考察了非圆形状的异形工艺孔及其位置布局对局部应力释放的作用。在现有模具拉深筋和模具压边圈压边力不调整的情况下,优化了带异形工艺孔的多边形坯料,解决了产品冲压成形过程中内部破裂和边缘起皱的问题。
The back door inner panel has complex stress and strain field during plastic forming because of its complex structure.According to the theoretical analysis of the stress state around the hole in the blank,material removal and irregular holes opening were conducted in the four corners and central structural mutation area in order to improve the material flow uniformity and reduce the local stress concentration by using local stress release method.The simulation results of multiple schemes were obtained based on finite element modeling technology,which were verified by the field test.The influence of non-circular and irregular hole and its position on the local stress release was focused on.Without adjustment of drawbead and blank holder force,the polygon blank with irregular holes was optimized.And the problems of internal cracks and edge wrinkles in the stamping process were solved.
The back door inner panel has complex stress and strain field during plastic forming because of its complex structure.According to the theoretical analysis of the stress state around the hole in the blank,material removal and irregular holes opening were conducted in the four corners and central structural mutation area in order to improve the material flow uniformity and reduce the local stress concentration by using local stress release method.The simulation results of multiple schemes were obtained based on finite element modeling technology,which were verified by the field test.The influence of non-circular and irregular hole and its position on the local stress release was focused on.Without adjustment of drawbead and blank holder force,the polygon blank with irregular holes was optimized.And the problems of internal cracks and edge wrinkles in the stamping process were solved.
引文
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[2]熊火轮.计算机辅助板料成形分析模拟系统[D].北京:北京航空航天大学,1990.XIONG Huolun.Analysis and simulation system for sheet metal forming by computer[D].Beijing:Beihang University,1990.
[3]KIM Y H,PARK J J.Effect of process parameters on formability in incremental forming of sheet metal[J].Journal of Materials Processing Technology,2002,s 130-s 131(4):42-46.
[4]WEI G,WAGONER R H.Die design method for sheet springback[J].International Journal of Mechanical Sciences,2004,46(7):1097-1113.
[5]龚志辉,兰质纯,周顺峰,等.汽车覆盖件模具凸型面拉延方法[J].机械工程学报,2014,50(20):129-135.GONG Zhihui,LAN Zhichun,ZHOU Shunfeng,et al.Method on convex surface drawing for automobile panel[J].Chinese Journal of Mechanical Engineering,2014,50(20):129-135.
[6]余江鸿,胡成武,占奇锋,等.轴对称带孔板拉深-翻孔复合变形的实验研究[J].塑性工程学报,2010,17(6):14-17.YU Jianghong,HU Chengwu,ZHAN Qifeng,et al.Experimental study on composite deformation of drawing-flanging for axisy mmetric holed slab[J].Journal of Plasticity Engineering,2010,17(6):14-17.
[7]陈泷,陈炜,王祥,等.汽车覆盖件多步成形工艺设计[J].塑性工程学报,2014,21(1):13-17.CHEN Long,CHEN Wei,WANG Xiang,et al.Proces design of multi-step forming of automobile panel[J].Journal of Plasticity Engineering,2014,21(1):13-17.
[8]李文明,谷晓玉.汽车后背门内板起皱解决措施[J].模具工业,2013,39(10):52-54.LI Wenming,GU Xiaoyu.Solutions to wrinkling of automobile back door inner panel[J].Die&Mould Industry,2013,39(10):52-54.
[9]胡平.汽车覆盖件模具设计[M].北京:机械工业出版社,2012.HU Ping.Design dies for the automobile body panel[M].Beijing:China Machine Press,2012.
[10]张家骅,陈炜,吕盾,等.发动机内罩板成形过程中工艺孔的设置[J].模具工业,2006,32(5):23-26.ZHANG Jiahua,CHEN Wei,LDun,et al.Research on designing the precess-hole's outline to improve the formability of inner hood[J].Die&Mould Industry,2006,32(5):23-26.