冲压件表面缺陷形成机理的试验与仿真研究
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摘要
本文根据汽车外覆盖件上经常出现的表面凹陷与畸变的产生特点,设计了壹套包含四种反拉延形状的冲压试验模具,用来分析表面凹陷与畸变产生的规律及机理。同时为了监测表面缺陷产生时,在试件“A”表面上产生缺陷区域的应变及位移变化规律,本文设计了两套测量系统,即在线适时测量应变与位移的动态测量系统与静态测量系统。通过冲压试验,在本文所设计的冲压试件“A”级表面上,成功地复制了汽车外覆盖件上经常产生的表面凹陷与畸变的缺陷。通过对试验结果与数值仿真结果的分析,研究了反拉延形状的三种特征尺寸变量对表面凹陷与畸变的影响规律,分析了冲压试件在成形过程中试件“A”级表面上应力分布及变化趋势,研究了表面凹陷与畸变产生的机理。
0.Preface
Fierce market competition has driven automotive manufacturers to improve the quality of their cars and trucks in every aspect The Class "A" surface,i.e.the exposed surface of a vehicle's outer panel,determines the appearance of the vehicle and needs to be clean. However,many defects such as die mark,draw line,skid line,loose metal,surface low, distortion,etc are frequently introduced into the Class "A" surface during the manufacturing process.In plants,time-consuming and costly die rework and manual panel finishing are required to clean up these defects.Among them,the surface distortion and skid line are the two most challenging problems,and difficult to resolve in physical tryouts.Up to date the origins of these defects have not been well understood.These two categories of surface defects can be generated in draw die operations or trim/flange die operations.Surface low and distortions are surface irregularities that deviate from the nominal design.The deviation may be caused by incomplete forming,insufficient stretching,buckling in the panel,or spring-back.The resolution of surface distortion can be achieved by revising product design or die development(binder,addendum and draw bead),or through adjusting binder travel and binder pressure etc.However,without a clear understanding of the root cause,all these remedies can only be performed on a trial-and-error basis.
In this paper our study was based on the project of National Natural Science Funds "the basic theory,calculation method and key technique of stamping and die design" and General Motor Grant "investigate and correct class "A" surface defects through experiments(draw die related surface low and distortion)".We designed a serious of experiments dies which represented the surface distortion and low of auto panel.Moreover,we also designed dynamic and stable measuring system.We analyzed the root-cause and mechanism of surface distortion based on stamping tests and numerical simulation.
1.Technical details of the experiment die
We designed experimental dies containing representative automobile outer panel product features that usually cause surface low and distortion.Prior to designing the dies,we collected and reviewed the typical product features in automotive outer panels.The geometry of a typical depression feature can be described by five design variables: Depression Depth(H),Upper Sectional Radius(R_U),Lower Sectional Radius(R_L),Plan View Radius(R_P) and Plan View Angle(α_p).The values of the five design variables vary from part to part.In practice,however,only the Plan View Radius Rp,Plan View Angleα_P and Depth H vary in a wide range.For example,the plan view angle can be anywhere from 60°to 240°.The upper sectional radius R_U and lower sectional radius R_L do not vary as much. In our design of the experiment,for simplicity,we considered variation of Rp,α_P and H while keeping R_U and R_L constant.To reduce material and construction costs through utilizing common die components,we made die inserts for these product features.The plan view angle of each insert takes one of four values(α_P=60°,90°,120°,240°) and the plan view radius has four variations(R_P=10mm,20mm,30mm,40mm) in each insert(exact values to be determined).There different depression depths have been experimented.
2.Stamping test and numerical Simulation
We did stamping test of the four different redrawing characters.The surface defects can be seen around the corner of finish panels after fiction of oilstone.The preliminary tryout on these experimental dies was carried using CR4 steel,a typical material for exterior panels. Various static measurements and dynamic measurements were performed.The measurement results have shown that the designed experimental dies successfully replicated the surface distortion phenomena,which are very common in automotive surface panels.These results suggested the experimental dies,which we designed can replicate the surface defects phenomena,which are very common in automobile's outer panel.
3.Correct test correct simulation of surface defects
We designed three types of test and simulations calculations about correct solution for the surface distortion.The first method was no gap between die and panel after stamping. The results of simulation and examination showed that the surface low has been improved but there was still micro-distortion on the die.The surface distortion can be removed by the second correct solution according the results of experiment and simulation.We only did the simulation of the third solution,and the simulation results showed the low and distortion reduced obviously.
0.Preface
Fierce market competition has driven automotive manufacturers to improve the quality of their cars and trucks in every aspect The Class "A" surface,i.e.the exposed surface of a vehicle's outer panel,determines the appearance of the vehicle and needs to be clean. However,many defects such as die mark,draw line,skid line,loose metal,surface low, distortion,etc are frequently introduced into the Class "A" surface during the manufacturing process.In plants,time-consuming and costly die rework and manual panel finishing are required to clean up these defects.Among them,the surface distortion and skid line are the two most challenging problems,and difficult to resolve in physical tryouts.Up to date the origins of these defects have not been well understood.These two categories of surface defects can be generated in draw die operations or trim/flange die operations.Surface low and distortions are surface irregularities that deviate from the nominal design.The deviation may be caused by incomplete forming,insufficient stretching,buckling in the panel,or spring-back.The resolution of surface distortion can be achieved by revising product design or die development(binder,addendum and draw bead),or through adjusting binder travel and binder pressure etc.However,without a clear understanding of the root cause,all these remedies can only be performed on a trial-and-error basis.
In this paper our study was based on the project of National Natural Science Funds "the basic theory,calculation method and key technique of stamping and die design" and General Motor Grant "investigate and correct class "A" surface defects through experiments(draw die related surface low and distortion)".We designed a serious of experiments dies which represented the surface distortion and low of auto panel.Moreover,we also designed dynamic and stable measuring system.We analyzed the root-cause and mechanism of surface distortion based on stamping tests and numerical simulation.
1.Technical details of the experiment die
We designed experimental dies containing representative automobile outer panel product features that usually cause surface low and distortion.Prior to designing the dies,we collected and reviewed the typical product features in automotive outer panels.The geometry of a typical depression feature can be described by five design variables: Depression Depth(H),Upper Sectional Radius(R_U),Lower Sectional Radius(R_L),Plan View Radius(R_P) and Plan View Angle(α_p).The values of the five design variables vary from part to part.In practice,however,only the Plan View Radius Rp,Plan View Angleα_P and Depth H vary in a wide range.For example,the plan view angle can be anywhere from 60°to 240°.The upper sectional radius R_U and lower sectional radius R_L do not vary as much. In our design of the experiment,for simplicity,we considered variation of Rp,α_P and H while keeping R_U and R_L constant.To reduce material and construction costs through utilizing common die components,we made die inserts for these product features.The plan view angle of each insert takes one of four values(α_P=60°,90°,120°,240°) and the plan view radius has four variations(R_P=10mm,20mm,30mm,40mm) in each insert(exact values to be determined).There different depression depths have been experimented.
2.Stamping test and numerical Simulation
We did stamping test of the four different redrawing characters.The surface defects can be seen around the corner of finish panels after fiction of oilstone.The preliminary tryout on these experimental dies was carried using CR4 steel,a typical material for exterior panels. Various static measurements and dynamic measurements were performed.The measurement results have shown that the designed experimental dies successfully replicated the surface distortion phenomena,which are very common in automotive surface panels.These results suggested the experimental dies,which we designed can replicate the surface defects phenomena,which are very common in automobile's outer panel.
3.Correct test correct simulation of surface defects
We designed three types of test and simulations calculations about correct solution for the surface distortion.The first method was no gap between die and panel after stamping. The results of simulation and examination showed that the surface low has been improved but there was still micro-distortion on the die.The surface distortion can be removed by the second correct solution according the results of experiment and simulation.We only did the simulation of the third solution,and the simulation results showed the low and distortion reduced obviously.
引文
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