摘要
为了解决某车型前地板左右边梁开裂和回弹的缺陷,提高效率,降低模具改模次数,采用有限元软件Autoform进行全工序冲压过程模拟,以最大减薄率和最大回弹量为评价指标,对压边力、模具间隙、冲压速度、摩擦因数进行优化。通过单因素控制变量法,得到工艺参数的合理取值范围。通过正交试验得到最优工艺参数组合为:压边力为1000 kN、模具间隙为1.5 mm、冲压速度为100 mm·s^(-1)、摩擦因数为0.13,其中,冲压速度对目标影响最小。工艺参数优化以及对模具型面进行迭代补偿后模拟结果显示:最大减薄率降低至20.6%,消除了开裂风险;左边梁的最大回弹量为0.534 mm、右边梁为0.867 mm。通过试模验证,制件无开裂且回弹量基本满足±1.0 mm的尺寸偏差。通过工艺参数优化和模具型面部分迭代补偿的方式,避免了零件开裂风险,提高了零件尺寸精度,减少了模具改模次数。
In order to solve the cracking and springback defects of left and right side rails for the front floor of a certain vehicle model and improve the efficiency and reduce the number of die modifications,the stamping process of the entire process was simulated by finite element software Autoform.Then,taking the maximum thinning rate and maximum springback amount as evaluation indicators,the blanking holding force,die clearance,stamping speed and friction coefficient were optimized,and the reasonable value ranges of process parameters were obtained by the single factor control variable method.Furthermore,the optimal process parameters combination was obtained as the blanking holding force of 1000 kN,the die clearance of 1.5 mm,the stamping speed of 100 mm·s^(-1),and the friction coefficient of 0.13 by the orthogonal experiment,and among them,the stamping speed has the least impact on the target.The simulation results after process parameter optimization and iterative compensation of die surface show that the maximum thinning rate is decreased to 20.6%,eliminating the risk of cracking,and the maximum springback amounts of left and right side rails are 0.534 mm and 0.867 mm,respectively.The die verification shows that the parts have no cracking and the springback amount basically meets the size deviation of±1.0 mm.Thus,through process parameter optimization and partial iterative compensation of die surface,the risk of part cracking is avoided,the dimensional accuracy of part is improved,and the number of die modifications is reduced.
作者
占贝贝
张元好
李兵
徐飞越
Zhan Beibei;Zhang Yuanhao;Li Bing;Xu Feiyue(School of Automotive Materials,Hubei University of Automotive Technology,Shiyan 442000,China)
出处
《锻压技术》
北大核心
2025年第5期136-146,共11页
Forging & Stamping Technology
基金
湖北省科技重大专项(2022AAA001)
湖北省重点研发项目(2021BAB019)。
关键词
板料成形
冲压工艺
减薄率
回弹量
回弹补偿
sheet forming
stamping process
thinning ratio
springback amount
springback compensation
