轿车骨架件级进模开发技术研究与应用
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摘要
板料冲压成形是轿车车身制造的关键技术。传统的冲压技术不适合加工复杂零件,难以保证加工精度、生产效率低,而多工位级进模可以配合高速的冲压设备,附加自动送料机构,实现高速自动化冲压生产、稳定冲件质量,大大提高了生产效率。因此,采用级进模实现板料多步成形是非常重要的。
本文以轿车骨架件级进模设计为例,研究了轿车零件的多步成形过程。采用理论分析方法,初步确定级进模的成形工艺方案,通过数值模拟技术对工艺方案进行修改,然后通过试验验证工艺方案设计的合理性,进而优化工艺方案,最终得出合理的工艺方案。接着对级进模结构设计进行研究,为级进模结构设计提供了方法。
第二章:研究了传统的薄板成形的基本理论与数值模拟技术,研究了板料冲压成形的几种变形方式,讨论了板料成形工艺控制的方法,以及数值模拟技术在板料多步成形中的应用。
第三章:以轿车骨架件级进模设计工艺为例,分析轿车骨架件的零件图,采用传统的经验公式,初步确定轿车骨架件的成形工艺,然后采用单工位多工序有限元建模及模拟方法,研究了轿车骨架件级进模各个工步的成形情况,优化零件的成形工艺,再结合实冲试验,确定了合理的零件的生产工艺,从而阐明了多工位级进模实现板料多步冲压成形的过程。
第四章:首先分析了级进模结构设计的原则,然后通过轿车骨架件的成形工艺,对轿车骨架件多工位级进模结构进行概要设计,进而设计级进模结构的主要零件,设计出一套完整的轿车骨架件级进模装配图,通过计算板料冲压过程的冲裁力,选择合适的冲压设备,然后进行实冲试验,通过试验验证,证明多工位级进模设计过程的有效性。
Sheet metal stamping is a highly-efficient and economic processing method which can achieve automobile body lightening technology. Traditional stamping technology is unsuitable for processing complex parts, as it's hard to ensure the processing precision with low production efficiency. Moreover, the multi-operation progressive die can cooperate with high-speed stamping equipment, with additional automatic feeding mechanism which can realize high-speed automatic stamping production and stabilize the quality of stamping pieces that can enhance the production efficiency greatly. Therefore, it is of great importance that using progressive die to realize sheet metal stamping.
In this study, the production of processing of automatic complex parts, with an example of automatic structure pieces is investigated. Based on theoretic analysis, it is ensured the figuration craft project of progressive die primarily. Then the project can be optimized and amended by using the numerical simulation technology. Moreover, the rationality of project can be validated by experiment, finally the reasonable craft project can be ascertained. The following work is designing the structures of progressive die, which can provide theoretic instructions with intending design technology investigations.
In the second chapter, traditional sheet metal stamping theories and numerical simulation method are presented, several transfigurations modes of sheet metal stamping are studied, the manipulations of sheet processing craft are discussed, and the multi-operation of sheet metal is studied by applying numerical simulation method.
In the third chapter, taking automobile structure pieces for example, the part drawing are analyzed, primarily the figuration crafts. Then the figuration craft of each step of automobile structure pieces is studied by using multi-operation single working procedure finite element modeling and simulating methods and optimized the parameters of the crafts. Combined with practical production, the reasonable production craft could be determined, and the process of sheet metal stamping could be illustrated clearly.
In the fourth chapter, the principle of the structure design of progressive die is analyzed. The general structure of automobile structure pieces progressive die with the assured figuration craft is designed, and the structures of the critical parts is devised. Moreover, a suit of integrate mould assemble drawing of automobile structure pieces progressive die is designed. The pressing forces of stamping are calculated. The practical stamping experiment can be put up with appropriate punch facility, and the whole design can be assured by examination validating.
本文以轿车骨架件级进模设计为例,研究了轿车零件的多步成形过程。采用理论分析方法,初步确定级进模的成形工艺方案,通过数值模拟技术对工艺方案进行修改,然后通过试验验证工艺方案设计的合理性,进而优化工艺方案,最终得出合理的工艺方案。接着对级进模结构设计进行研究,为级进模结构设计提供了方法。
第二章:研究了传统的薄板成形的基本理论与数值模拟技术,研究了板料冲压成形的几种变形方式,讨论了板料成形工艺控制的方法,以及数值模拟技术在板料多步成形中的应用。
第三章:以轿车骨架件级进模设计工艺为例,分析轿车骨架件的零件图,采用传统的经验公式,初步确定轿车骨架件的成形工艺,然后采用单工位多工序有限元建模及模拟方法,研究了轿车骨架件级进模各个工步的成形情况,优化零件的成形工艺,再结合实冲试验,确定了合理的零件的生产工艺,从而阐明了多工位级进模实现板料多步冲压成形的过程。
第四章:首先分析了级进模结构设计的原则,然后通过轿车骨架件的成形工艺,对轿车骨架件多工位级进模结构进行概要设计,进而设计级进模结构的主要零件,设计出一套完整的轿车骨架件级进模装配图,通过计算板料冲压过程的冲裁力,选择合适的冲压设备,然后进行实冲试验,通过试验验证,证明多工位级进模设计过程的有效性。
Sheet metal stamping is a highly-efficient and economic processing method which can achieve automobile body lightening technology. Traditional stamping technology is unsuitable for processing complex parts, as it's hard to ensure the processing precision with low production efficiency. Moreover, the multi-operation progressive die can cooperate with high-speed stamping equipment, with additional automatic feeding mechanism which can realize high-speed automatic stamping production and stabilize the quality of stamping pieces that can enhance the production efficiency greatly. Therefore, it is of great importance that using progressive die to realize sheet metal stamping.
In this study, the production of processing of automatic complex parts, with an example of automatic structure pieces is investigated. Based on theoretic analysis, it is ensured the figuration craft project of progressive die primarily. Then the project can be optimized and amended by using the numerical simulation technology. Moreover, the rationality of project can be validated by experiment, finally the reasonable craft project can be ascertained. The following work is designing the structures of progressive die, which can provide theoretic instructions with intending design technology investigations.
In the second chapter, traditional sheet metal stamping theories and numerical simulation method are presented, several transfigurations modes of sheet metal stamping are studied, the manipulations of sheet processing craft are discussed, and the multi-operation of sheet metal is studied by applying numerical simulation method.
In the third chapter, taking automobile structure pieces for example, the part drawing are analyzed, primarily the figuration crafts. Then the figuration craft of each step of automobile structure pieces is studied by using multi-operation single working procedure finite element modeling and simulating methods and optimized the parameters of the crafts. Combined with practical production, the reasonable production craft could be determined, and the process of sheet metal stamping could be illustrated clearly.
In the fourth chapter, the principle of the structure design of progressive die is analyzed. The general structure of automobile structure pieces progressive die with the assured figuration craft is designed, and the structures of the critical parts is devised. Moreover, a suit of integrate mould assemble drawing of automobile structure pieces progressive die is designed. The pressing forces of stamping are calculated. The practical stamping experiment can be put up with appropriate punch facility, and the whole design can be assured by examination validating.
引文
[1]牟林,胡建华.冲压工艺与模具设计.北京:北京大学出版社,2006.8
[2]姜奎华.冲压工艺与模具设计.北京:机械工业出版社,1997
[3]侯义馨.冲压工艺及模具设计.北京:兵器工业出版社,1999
[4]欧阳波仪.多工位级进模设计标准教程.北京:化学工业出版社,2008.10
[5]王同海.实用冲压技术.北京:机械工业出版社,1995.4
[6]谷维亮,陈炜,贝建伟,等.基于转矩平衡和数值模拟的级进模压力中心优化方法[J].模具工业,2008,34(9):32-36.
[7]李畅,李建军,温建勇,肖祥芷.基于UG的关联设计技术及其在级进模CAD系统中的应用[J].中国机械工程.2002(11):1967-1970.
[8]钟亦棋,陈扬,赵震,等.基于知识的支持自顶向下的级进模结构设计技术[J].上海交通大学学报.2003(12):1887-1890.
[9]徐波,李建军,张祥林,肖样芷.基于关联设计的弯曲级进模结构CAD方法研究[J].塑性工程学报.2005(6):83-87.
[10]张华.连接端子多工位级进模设计.锻压技术.2009,34(5):26-29
[11]邓毅.连接支架多工位级进模设计.模具工业.2009,35(10):20-23
[12]崔东风.浅析级进模设计的几个要点.模具制造.2009(9):54-58
[13]Zhang Zhibing,Liu Yuqi,Du Ting,Li Zhigang.Blank design and formability prediction of complicated progressive die stamping part using a multi-step unfolding method,journal of materials processing technology 205(2008) 425-431
[14]Jian,L.,Xianghuai,D.,Zhigang,L.,2002.FE inverse approach and evaluation for design of sheet metal forming progress.China Mech.Eng.13,826-829.
[15]Guo,Y.Q.,Batoz,J.L.,Detraux,J.M.,Duroux,P.,1990.Finite element procedures for strain estimations of sheet metal forming parts.Int.J.Num.Method Eng.30,1385-1401.
[16]Guo,Y.Q.,Batoz,J.L.,Naceur,H.,et al.,2000.Recent development on the analysis and optimum design of sheet metal forming parts using a simplified inverse approach.Comput.Struct.78,133-148.
[17]Guo,Y.Q.,Gati,W.,Naceur,H.,Batoz,J.L.,2001.Springback evaluation after forming simulation using the inverse approach and incremental approach,simulation of materials processing:theory,methods and applications.Swets Zeitlinger,717-722.
[18]Naceur,H.,Guo,丫 q,Batoz,J.L.,Knopf-Lenoir,C.,2001.Optimization of drawbead restraining forces and drawbead design in sheet metal forming process.Int.J.Mech.Sci.43,2407-2434
[19]Yuqi,L.,Zhigang,L.,Yakun,Y.,2004.Fast accurate prediction of blank shape in sheet metal stamping forming.Acta Mechanica Solida Sin.17,36-42
[20]R.M.Duffy,S.Qiang,Knowledge based design of progressive stamping dies,J.Mater.Process.Technol.28(1991) 221-227.
[21]Y.K.D.V.Prasad,Some studies on problems associated with automated design of cutting dies for sheet metal,Ph.D.Thesis,Dept.of Mech.Eng.,IIT,Bombay,India,1992.
[22]陈炜,王晓路,高霖.板料多步冲压回弹的数值模拟研究.塑性工程学报.2005,12(5):8-12
[23]陈炜,杨继昌,仲志刚,方禾,朱国璋.车身结构件多步冲压工艺数值模拟.轿车工程.2003,25(5):518-522
[24]仲志刚,方禾,陈炜,吕盾,陈磊.基于数值模拟的车身结构件多步冲压工艺优化.轻型轿车技术.2004(3):33-37
[25]叶俊勇,虞婕华.链板无搭边分体式准高速精密冲裁级进模设计.机械制造.2009,47(541):72-75
[26]欧阳波仪,林启权.基于CBR的多工位精密级进模故障诊断系统的研究.模具技术.2009(5):13-17
[27]模具实用技术丛书编委.冲模设计应用实例.机械工业出版社,2006.3
[28]S.Sitaraman,G.L.Kimzel,T.Altan.Process sequence design for multi-stage forming of axisymmetric sheet metal parts.ERC for net shape manufacturing,report No.ERC/NSM-s-89-4.Ohio State University.Columbus,OH,1989
[29]杨玉英.大型薄板成形技术.北京:国防工业出版社,1996
[30]邓陟,王先进,陈鹤峥.金属薄板成形技术.北京:兵器工业出版社,1993
[31]梁炳文,陈孝戴,王志恒.板金成形性能.北京:机械工业出版社,1996
[32]William R.D.Wilson.Lubrication and Friction in Sheet Metal Forming.SAE Paper930807
[33]陶宏之,何丹农,等.研究拉深过程中摩擦与润滑规律.摩擦学报.2000
[34]You-Min Huang.Kuo-Hsiung Chien.Influence of the punch profile on the limitation of formability in the hole-flanging process.Journal of Materials of Processing Technology 113(2001):720-724
[35]周天端.轿车覆盖件冲压成形技术.北京:机械工业出版社,2000
[36]王新华.汽车冲压技术.北京:北京理工大学出版社,1999
[37]李尚健.金属塑性成形过程模拟.北京:机械工业出版社,1999
[38]吴国勇.板料成形过程数值模拟研究.华中理工大学博士学位论文,1995
[39]刘罡.基于回弹控制的提高轿车冲压件成形精度方法研究.上海交通大学博士论文,2001
[40]彭颖红.金属塑性成形仿真技术.上海:上海交通大学,1999
[41]S.Fromention,M.Marting,G.Ferron,Z.Tourki,L.P.Moreira,G.Ferran.Finite element simulations of sheet-metal forming processes for planar-anisotropic materials.International Journal of Mechanical Sciences,43(2000):1833o 1852
[42]R.Kergen,P.Jodogne.Computerized Control of the Blank holder Pressure on Deep Drawing Press[C].SRE Paper No.920433.SAE SP-897,1992
[43]王娟.级进模冲压力和压力中心的确定及优化方法研究.江苏大学硕士学位论文.2008.6
[44]王新华,陈登.简明冲模设计手册.机械工业出版社,2008.7
[2]姜奎华.冲压工艺与模具设计.北京:机械工业出版社,1997
[3]侯义馨.冲压工艺及模具设计.北京:兵器工业出版社,1999
[4]欧阳波仪.多工位级进模设计标准教程.北京:化学工业出版社,2008.10
[5]王同海.实用冲压技术.北京:机械工业出版社,1995.4
[6]谷维亮,陈炜,贝建伟,等.基于转矩平衡和数值模拟的级进模压力中心优化方法[J].模具工业,2008,34(9):32-36.
[7]李畅,李建军,温建勇,肖祥芷.基于UG的关联设计技术及其在级进模CAD系统中的应用[J].中国机械工程.2002(11):1967-1970.
[8]钟亦棋,陈扬,赵震,等.基于知识的支持自顶向下的级进模结构设计技术[J].上海交通大学学报.2003(12):1887-1890.
[9]徐波,李建军,张祥林,肖样芷.基于关联设计的弯曲级进模结构CAD方法研究[J].塑性工程学报.2005(6):83-87.
[10]张华.连接端子多工位级进模设计.锻压技术.2009,34(5):26-29
[11]邓毅.连接支架多工位级进模设计.模具工业.2009,35(10):20-23
[12]崔东风.浅析级进模设计的几个要点.模具制造.2009(9):54-58
[13]Zhang Zhibing,Liu Yuqi,Du Ting,Li Zhigang.Blank design and formability prediction of complicated progressive die stamping part using a multi-step unfolding method,journal of materials processing technology 205(2008) 425-431
[14]Jian,L.,Xianghuai,D.,Zhigang,L.,2002.FE inverse approach and evaluation for design of sheet metal forming progress.China Mech.Eng.13,826-829.
[15]Guo,Y.Q.,Batoz,J.L.,Detraux,J.M.,Duroux,P.,1990.Finite element procedures for strain estimations of sheet metal forming parts.Int.J.Num.Method Eng.30,1385-1401.
[16]Guo,Y.Q.,Batoz,J.L.,Naceur,H.,et al.,2000.Recent development on the analysis and optimum design of sheet metal forming parts using a simplified inverse approach.Comput.Struct.78,133-148.
[17]Guo,Y.Q.,Gati,W.,Naceur,H.,Batoz,J.L.,2001.Springback evaluation after forming simulation using the inverse approach and incremental approach,simulation of materials processing:theory,methods and applications.Swets Zeitlinger,717-722.
[18]Naceur,H.,Guo,丫 q,Batoz,J.L.,Knopf-Lenoir,C.,2001.Optimization of drawbead restraining forces and drawbead design in sheet metal forming process.Int.J.Mech.Sci.43,2407-2434
[19]Yuqi,L.,Zhigang,L.,Yakun,Y.,2004.Fast accurate prediction of blank shape in sheet metal stamping forming.Acta Mechanica Solida Sin.17,36-42
[20]R.M.Duffy,S.Qiang,Knowledge based design of progressive stamping dies,J.Mater.Process.Technol.28(1991) 221-227.
[21]Y.K.D.V.Prasad,Some studies on problems associated with automated design of cutting dies for sheet metal,Ph.D.Thesis,Dept.of Mech.Eng.,IIT,Bombay,India,1992.
[22]陈炜,王晓路,高霖.板料多步冲压回弹的数值模拟研究.塑性工程学报.2005,12(5):8-12
[23]陈炜,杨继昌,仲志刚,方禾,朱国璋.车身结构件多步冲压工艺数值模拟.轿车工程.2003,25(5):518-522
[24]仲志刚,方禾,陈炜,吕盾,陈磊.基于数值模拟的车身结构件多步冲压工艺优化.轻型轿车技术.2004(3):33-37
[25]叶俊勇,虞婕华.链板无搭边分体式准高速精密冲裁级进模设计.机械制造.2009,47(541):72-75
[26]欧阳波仪,林启权.基于CBR的多工位精密级进模故障诊断系统的研究.模具技术.2009(5):13-17
[27]模具实用技术丛书编委.冲模设计应用实例.机械工业出版社,2006.3
[28]S.Sitaraman,G.L.Kimzel,T.Altan.Process sequence design for multi-stage forming of axisymmetric sheet metal parts.ERC for net shape manufacturing,report No.ERC/NSM-s-89-4.Ohio State University.Columbus,OH,1989
[29]杨玉英.大型薄板成形技术.北京:国防工业出版社,1996
[30]邓陟,王先进,陈鹤峥.金属薄板成形技术.北京:兵器工业出版社,1993
[31]梁炳文,陈孝戴,王志恒.板金成形性能.北京:机械工业出版社,1996
[32]William R.D.Wilson.Lubrication and Friction in Sheet Metal Forming.SAE Paper930807
[33]陶宏之,何丹农,等.研究拉深过程中摩擦与润滑规律.摩擦学报.2000
[34]You-Min Huang.Kuo-Hsiung Chien.Influence of the punch profile on the limitation of formability in the hole-flanging process.Journal of Materials of Processing Technology 113(2001):720-724
[35]周天端.轿车覆盖件冲压成形技术.北京:机械工业出版社,2000
[36]王新华.汽车冲压技术.北京:北京理工大学出版社,1999
[37]李尚健.金属塑性成形过程模拟.北京:机械工业出版社,1999
[38]吴国勇.板料成形过程数值模拟研究.华中理工大学博士学位论文,1995
[39]刘罡.基于回弹控制的提高轿车冲压件成形精度方法研究.上海交通大学博士论文,2001
[40]彭颖红.金属塑性成形仿真技术.上海:上海交通大学,1999
[41]S.Fromention,M.Marting,G.Ferron,Z.Tourki,L.P.Moreira,G.Ferran.Finite element simulations of sheet-metal forming processes for planar-anisotropic materials.International Journal of Mechanical Sciences,43(2000):1833o 1852
[42]R.Kergen,P.Jodogne.Computerized Control of the Blank holder Pressure on Deep Drawing Press[C].SRE Paper No.920433.SAE SP-897,1992
[43]王娟.级进模冲压力和压力中心的确定及优化方法研究.江苏大学硕士学位论文.2008.6
[44]王新华,陈登.简明冲模设计手册.机械工业出版社,2008.7