薄壁双曲率金属包边冲压起皱机理及控制方法  

Wrinkle mechanism and control method of thin-wall bi-curve metal shield in stamping

作　　者：陈一哲 付舒程 王辉[1,2] 胡志力[3,4] 华林[1,2,4] CHEN Yi-zhe;FU Shu-cheng;WANG Hui;HU Zhi-li;HUA Lin(Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan University of Technology,Wuhan 430070,China;Hubei Longzhong Laboratory,Wuhan University of Technology,Xiangyang 441000,China;Hubei Engineering Technology Research Center for Material Green Precision Forming,Wuhan University of Technology,Wuhan 430070,China;School of Automotive Engineering,Wuhan University of Technology,Wuhan 430022,China)

机构地区：[1]武汉理工大学现代汽车零部件技术湖北省重点实验室,湖北武汉430070 [2]武汉理工大学湖北隆中实验室,湖北襄阳441000 [3]武汉理工大学湖北省材料绿色精密成形工程技术研究中心,湖北武汉430070 [4]武汉理工大学汽车工程学院,湖北武汉430022

出　　处：《塑性工程学报》2022年第11期42-52,共11页Journal of Plasticity Engineering

基　　金：国家自然科学基金资助项目(52175360);青年人才托举工程(2021QNRC001);中国博士后科学基金资助项目(2022T150278,2022M710062)。

摘　　要：针对薄壁双曲率金属包边在冲压过程中由于抗失稳能力弱、变形不均匀而容易塑性失稳产生起皱的问题,提出了采用分区压边与弯曲压边的方法以控制起皱缺陷。对304不锈钢板进行力学性能测试,获得了材料模型参数,建立了分区压边和弯曲压边的有限元分析模型,根据正交法则对凹模圆角半径、模具间隙和板料轧制方向进行了3因素2水平试验设计。通过将方形薄板能量法理论与有限元方形壳单元结合,编写了以能量法理论为核心的M程序,实现了对板料模型起皱现象的定量分析,揭示了起皱机理。分析了工艺参数对板厚均匀性与起皱水平的影响程度并进行了参数优化,基于最优工艺参数开展了冲压工艺试验。有限元仿真、能量法理论分析与试验的结果表明,采用弯曲压边模具,薄壁双曲率金属包边成形质量良好,起皱缺陷得到了抑制。Aiming at the problem that the thin-wall bi-curve metal shield is prone to plastic instabillity and wrinkle due to its weak anti-buckling ability and uneven deformation in stamping,the method with segmented blank holder and bending blank holder to control the wrinkle defect was proposed.The mechanical properies test of 304 stainless steel plate was carried out and the material model parameters were obtained.The finite element analysis models of segmented blank holder and bending blank holder were established.According to orthogonal rule,the three-factors and two-levels test design for the die fillet radius,die clearance and blank rolling direction was carried out.By combining the theory of energy method of square thin plate with the finite element square shell element,the M program with the theory of energy method as the core was compiled to realize the quantitative analysis of the wrinkle phenomenon of plate model,and the wrinkle mechanism was revealed.The influence degree of process parameters on plate thickness uniformity and wrinkle level was analyzed and the parameter optimization was carried out.Based on the optimal process parameters,the stamping process tests were carried out.The results of finite element simulation,theoretical analysis of energy method and tests show that the forming quality of thin-wall bi-curve metal shield is good and the wrinkle defects are inhibited by using bending blank holder.

关 键 词：304不锈钢 复材桨叶金属包边 冲压成形 起皱机理与控制 弯曲压边 

分 类 号：TG386.41[金属学及工艺—金属压力加工]