中国标准动车组前端三维蒙皮件冲压成形  

Stamping of front-end three-dimensional skin of China electric multiple units

作　　者：谷诤巍[1] 吕萌萌[1] 张文学[1] 雷娇娇 徐虹[1] GU Zheng-wei LYU Meng-meng ZHANG Wen-xue LEI Jiao- jiao XU Hong(College of Materials Science and Engineering^ Ji l in University, Changchun 130022 , China)

机构地区：[1]吉林大学材料科学与工程学院,长春130022

出　　处：《吉林大学学报（工学版）》2017年第3期869-875,共7页Journal of Jilin University:Engineering and Technology Edition

基　　金：国家青年科学基金项目(51301074);吉林省科技发展计划项目(2013010201JC;20160204058GX)

摘　　要：以中国标准动车组前端三维蒙皮件为例,利用通用有限元软件Autoform对该类厚度大、拉延深度浅、空间结构复杂、非对称的V型截面蒙皮件的成形过程进行了模拟分析。研究了压边力、拉延筋、凹模圆角、拉延深度、摩擦因数及模具间隙等工艺和结构参数对蒙皮件成形的影响。分析了该类构件拉伸不足及轮廓精度差等成形缺陷的成因,并提出了相应的控制方法。结果表明:拉伸不足主要由成形过程中板料的流动阻力不足引起,可通过增大压边力、设置拉延筋进行控制,对于本文所研究的长条形蒙皮件而言,采用变强度拉延筋可以有效控制拉伸不足;轮廓精度差主要由回弹量大引起,优化成形工艺参数可一定程度上提高蒙皮件轮廓精度,工艺参数对轮廓精度的影响程度按照从大到小排序为:凹模圆角、摩擦因数、模具间隙、拉延深度;基于回弹量对模具型面进行补偿可以有效控制蒙皮件的轮廓精度;对于4 mm厚5083-H111铝合金蒙皮件而言,回弹补偿系数取1.2时,蒙皮件的轮廓精度最好。基于模拟结果开展了成形试验,得到合格的成形件,验证了缺陷控制措施的有效性。The forming process of the front-end three-dimensional skin of China Electric Multiple Units （CEMU） was simulated and analyzed using the general finite element software Autoform. The influences of the process parameters such as blankholder force, drawbead, die radius, draw depth, friction coefficient and die gap on the forming of the V-section skin with large thickness, shallow drawing depth and twisted structure were investigated. The reasons for the forming defects such as insufficient stretching and poor contour accuracy were analyzed and the controlling methods were proposed. The results show that insufficient stretching is mainly originated from the lack of flow resistance, which can be controlled by setting proper drawbead and increasing the blankholder force; for the investigated long strip skin in this work, variable intensity drawbead is recommended. Poor contour accuracy is mainly caused by large springback. Process parameter optimization can improve the contour accuracy to some extent, and degrees of the influence parameters are in the order： die radius 〉 friction coefficient 〉 die gap 〉 draw depth. Compensation to the surface based onspringback can significantly control the contour accuracy. For the 4 mm 5083-Hill aluminum alloy, the optimal compensation is 1.2 times of the springback amount. Forming tests were conducted according to the simulation results, and high quality compensations were achieved, which prove the validity of the proposed defect controlling methods.

关 键 词：材料合成与加工工艺 中国标准动车组 三维蒙皮 数值模拟 工艺参数 缺陷控制 

分 类 号：TG386[金属学及工艺—金属压力加工]