基于电磁辅助成形的汽车覆盖件成形工艺研究  

Research on the Forming Process of Automobile Panel Based on Electromagnetic Assisted Forming

作　　者：崔学习 万敏[1] 吴向东[1] 金铭 龙安林[1] CUI Xue-xi;WAN Min;WU Xiang-dong;JIN Ming;LONG An-lin(School of Mechanical Engineering and Automation,Beihang University,Beijing 100191,China)

机构地区：[1]北京航空航天大学机械工程及自动化学院,北京100191

出　　处：《精密成形工程》2021年第5期66-71,共6页Journal of Netshape Forming Engineering

基　　金：国家重点基础研究发展计划(973)(2011CB012800)。

摘　　要：目的为解决铝合金材料在冷冲压成形工艺中回弹量大、贴模度低、流动性差等问题,对汽车覆盖件的成形工艺进行研究。方法基于电磁场理论,结合电磁成形工艺,制定了首先采用冲压进行预成形然后通过电磁场辅助成形进行终成形的工艺方法,通过正交试验与有限元单向耦合分析相结合的方法获得了成形覆盖件的最佳工艺参数。结果基于正交试验获得了成形工艺参数的最佳组合:工位1采用峰值电压为8 kV、厚度为0.5 mm的单层线圈的成形参数,4个工步中的放电次数依次为22,28,36,44;工位2采用峰值电压为8 kV、厚度为0.5 mm的3层线圈的成形参数,4个工步中的放电次数依次为34,42,46,58。目标件的成形尺寸和理论尺寸对比结果表明,在最佳工艺组合下成形出目标件的误差较小且均匀分布在两圆角特征附近,“凸台”特征的成形误差相对较大,其最大误差为1.47 mm。结论通过成形试验,验证了所确定的成形工艺参数的有效性。在最佳工艺参数组合下,电磁辅助成形工艺结合冲压工艺可以应用于该汽车覆盖件的成形。In order to solve the problems of large spring-back,low die attachment and poor material formability in the cold stamping process of aluminum alloy materials,the forming process of automobile panel is researched and explored.Based on the electromagnetic field theory and combined with the electromagnetic forming process,a process method was developed that first uses ordinary stamping for pre-forming and then through electromagnetic assisted forming for final forming.Based on the orthogonal experiment,the best combination of forming process parameters is obtained:workplace 1 uses the forming parameters of a single-layer 0.5 mm coil with a peak voltage of 8 kV,and the discharge times in 4 steps are 22,28,36 and 44 times in sequence;and workplace 2 uses the forming parameters of a 3-layer 0.5 mm coil with a peak voltage of 8 kV,and the discharge times in 4 steps are 34,42,46 and 58 times in sequence.The comparison between the forming size of the targeted part and the theoretical size shows that the error of forming the targeted part under the best process combination is small and evenly distributed near the two fillet features.The forming error of the“boss”feature is relatively large,and its maximum error is 1.47 mm.Finally,the validity of the determined forming process parameters was verified by using the forming test.Then the electromagnetic assisted forming process can be combined with the stamping process to be applied to the forming of the automobile covers under the best combination of process parameters.

关 键 词：电磁辅助成形 有限元分析 板料成形 单向耦合分析 

分 类 号：TG391[金属学及工艺—金属压力加工]