优化滚边工艺提升车门区域尺寸匹配精度的方法研究
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摘要
目的研究滚边工艺参数对车门包边缩进量的影响,提升轿车车门区域的尺寸匹配精度。方法通过建立滚边压入角、TCP-RTP距离与车门包边缩进量的数学模型,得出了不同滚边压入角、TCP-RTP距离与包边缩进量的相互关系,提出了优化滚边工艺参数补偿车门钣金在冲压、焊接过程中的尺寸偏差的方法。在此基础上,结合改善某车型右后门与侧围间隙平行差的实例,计算了后门滚边压入角、TCP-RTP距离对应的包边缩进量,并与实际结果进行对比分析。结果滚边压入角θ越大,滚边后板件缩进量越大;TCP-RTP距离越大,滚边缩进量越小。结论提出的优化滚边压入角或TCP-RTP来实现板件滚边缩进量增大或减小的方法,能够在不更改模具的基础上提升车门外观匹配区域的质量。
The paper aims to study the influences of hemming parameters on dimensional variation of door to improve the matching accuracy of the vehicle doors. By setting up a mathematics model for the door roll in variation, hemming angle and TCP-RTP distance, the relationship among hemming angle, TCP-RTP distance and roll in variation was attained. And a method of improving the door dimensional accuracy to compensate the variation of the pressing and welding process was proposed. After that, in combination with an example of solving the gap parallelism between the rear door and the side panel, the roll in variation of the hemming angle and TCP-RTP distance was calculated and compared with the actual result. The roll in variation was enlarged with the increase of the hemming angle θ and decreased with the increase of the TCP-RTP distance. By optimizing the hemming angle and TCP-RTP distance to increase or decrease the roll in variation, the dimensional quality of vehicle door matching area can be improved without die modification.
The paper aims to study the influences of hemming parameters on dimensional variation of door to improve the matching accuracy of the vehicle doors. By setting up a mathematics model for the door roll in variation, hemming angle and TCP-RTP distance, the relationship among hemming angle, TCP-RTP distance and roll in variation was attained. And a method of improving the door dimensional accuracy to compensate the variation of the pressing and welding process was proposed. After that, in combination with an example of solving the gap parallelism between the rear door and the side panel, the roll in variation of the hemming angle and TCP-RTP distance was calculated and compared with the actual result. The roll in variation was enlarged with the increase of the hemming angle θ and decreased with the increase of the TCP-RTP distance. By optimizing the hemming angle and TCP-RTP distance to increase or decrease the roll in variation, the dimensional quality of vehicle door matching area can be improved without die modification.
引文
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[14]卢妍,张宁红,陈中春,等.汽车开启件滚边工艺缺陷控制方法研究[J].模具技术,2015(4):1-4.LU Yan,ZHANG Ning-hong,CHEN Zhong-chun,et al.Research on Defect Control Methods for Robotic Roller Hemming Process of Autobody Components[J].Die&Mould Technology,2015(4):1-4.
[15]王丽娟.滚压包边成形缺陷的研究[J].现代制造技术与装备,2016,51(7):17-18.WANG Li-juan.Study on Roller Hemming Forming Defects[J].Modern Manufacturing Technology&Equipment,2016,51(7):17-18.
[16]张均华,刘渝,杨睿,等.滚压包边成形质量缺陷研究[J].制造业自动化,2015,37(3):26-28.ZHANG Jun-hua,LIU Yu,YANG Rui,et al.The Research of Quality Defect of Robot Roller Hemming[J].Manufacturing Automation,2015,37(3):26-28.
[2]林忠钦.汽车车身制造质量控制技术[M].北京:机械工业出版社,2005.LIN Zhong-qin.Quality Control Technology for Automobile Body Manufacturing[M].Beijing:China Machine Press,2005.
[3]包向军,蒋宏范,何丹农,等.轿车车门内板冲压成形计算机仿真[J].金属成形工艺,2000,18(4):19-22.BAO Xiang-jun,JIANG Hong-fan,HE Dan-nong,et al.Computer Simulation of Autobody inner Door Panel Stamping Process[J].Metal Forming Technology,2000,18(4):19-22.
[4]孙连福,楚伟峰,崔礼春,等.基于车身开发的尺寸链设计[J].精密成形工程,2011,3(5):77-82.SUN Lian-fu,CHU Wei-feng,CUI Li-chun,et al.Design of Dimension Chain on BIW Development[J].Journal of Netshape Forming Engineering,2011,3(5):77-82.
[5]武朋飞,张璐.汽车翼子板的前门区域尺寸匹配控制方法研究[J].精密成形工程,2018,10(4):145-150.WU Peng-fei,ZHANG Lu.Control of Dimension Match in Front Door-side Area of Automobile Fender[J].Journal of Netshape Forming Engineering,2018,10(4):145-150.
[6]NEUGEBAUER R,DROSSEL W G,RSSINGER M,et al.Roller Hemming Simulation:State of the Art and Application Limits[J].Key Engineering Materials,2014,611/612:1062-1070.
[7]GüRGEN,SELIM.Numerical Simulation of Roller Hemming Operation on Convex Edge-Convex Surface Parts[J].Advanced Engineering Forum,2016,15:75-84.
[8]刘程,赵亦希,胡星,等.基于轮廓尺寸变动量的三道次机器人滚压包边角度路径设计[J].塑性工程学报,2011,18(1):16-20.LIU Cheng,ZHAO Yi-xi,HU Xing,et al.Design of Angle Path Based on Part's Contour Dimensional Variation during Three-step Robot Roller Hemming[J].Journal of Plasticity Engineering,2011,18(1):16-20.
[9]朱久友.机器人滚边成形工艺研究[D].合肥:合肥工业大学,2013.ZHU Jiu-you.Study on Roller Hemming Process[D].Hefei:Hefei University of Technology,2013.
[10]王立影,孙志成,卢兵兵,等.机器人滚边技术与应用[J].制造业自动化,2010,32(1):51-53.WANG Li-ying,SUN Zhi-cheng,LU Bing-bing,et al.Robot Roller Hemming Technology and Application[J].Manufacturing Automation,2010,32(1):51-53.
[11]李萍,井碧臣,黄彪,等.1100铝合金双滚轮滚压包边模拟及实验研究[J].精密成形工程,2018,10(2):92-98.LI Ping,JING Bi-chen,HUANG Biao,et al.Simulation and Experimental Study on Double-Roller Rolling Hemming Process of 1100 Aluminum Alloy[J].Journal of Netshape Forming Engineering,2018,10(2):92-98.
[12]杨竹君.机器人滚边工艺及系统研究[D].合肥:合肥工业大学,2012.YANG Zhu-jun.Study on Roller Hemming Process and System[D].Hefei:Hefei University of Technology,2012.
[13]伍俊棠,赵亦希,李淑慧,等.滚压包边角度对包边件轮廓尺寸变动的影响[J].锻压技术,2010,35(3):29-33.WU Jun-tang,ZHAO Yi-xi,LI Shu-hui,et al.Effect of Hemming Angle on Dimensional Deviation during Roller Hemming Process[J].Forging&Stamping Technology,2010,35(3):29-33.
[14]卢妍,张宁红,陈中春,等.汽车开启件滚边工艺缺陷控制方法研究[J].模具技术,2015(4):1-4.LU Yan,ZHANG Ning-hong,CHEN Zhong-chun,et al.Research on Defect Control Methods for Robotic Roller Hemming Process of Autobody Components[J].Die&Mould Technology,2015(4):1-4.
[15]王丽娟.滚压包边成形缺陷的研究[J].现代制造技术与装备,2016,51(7):17-18.WANG Li-juan.Study on Roller Hemming Forming Defects[J].Modern Manufacturing Technology&Equipment,2016,51(7):17-18.
[16]张均华,刘渝,杨睿,等.滚压包边成形质量缺陷研究[J].制造业自动化,2015,37(3):26-28.ZHANG Jun-hua,LIU Yu,YANG Rui,et al.The Research of Quality Defect of Robot Roller Hemming[J].Manufacturing Automation,2015,37(3):26-28.