汽车后地板拉延件成形裕度提升及参数优化研究  

Forming Margin Improvement and Parameter Optimization of Automotive Rear Floor Drawing Part

作　　者：韩文峰 揭招财 HANDISO Selamu Yisihak 袁斌先[1] HAN Wen-feng;JIE Zhao-cai;HANDISO Selamu Yisihak;YUAN Bin-xian(National-Local Joint Engineering Laboratory of Intelligent Manufacturing Oriented Automobile Die and Mould,School of Mechanical Engineering,Tianjin University of Technology and Education,Tianjin 300222,China)

机构地区：[1]天津职业技术师范大学机械工程学院汽车模具智能制造技术国家地方联合工程实验室,天津300222

出　　处：《精密成形工程》2023年第12期157-164,共8页Journal of Netshape Forming Engineering

基　　金：天津市教委科研计划(2020KJ106);天津市研究生科研创新项目(2022SKYZ159)。

摘　　要：目的提升拉延工艺处理后汽车后地板零件的成形裕度,优化成形参数。方法首先,设置初始拉延工艺参数:压边力为807kN、摩擦因数为0.135、压边圈行程为205mm、成形力为3572kN,基于Autoform软件对后地板的拉延工艺进行数值模拟。其次,利用全场网格应变测量技术对试冲件进行全场测量,获得全场成形裕度云图、成形极限图、减薄云图。最后,调节压边力与拉延筋深度及圆角半径,优化拉延工艺的成形参数。结果通过模拟获得了零件的潜在风险区域位置,零件的最大减薄率为24.10%、全场成形裕度均小于10%;测量结果表明,最大成形裕度为-9.29%。对风险区域进行模具圆角抛光后,最大成形裕度达到-10.65%。通过综合分析测量结果与模拟结果可知,采用压边力为782kN、B处拉延筋圆角半径为4.5mm、拉延筋深度为4.5 mm等成形参数,试冲得到的零件无开裂和起皱缺陷,成形裕度最大值为-14.33%,满足大规模生产需要。结论利用数值模拟结合全场网格应变测量技术指导修模作业并优化工艺参数,可以有效提升模具的调试效率。The work aims to improve the forming margin of automotive rear floor drawing part and optimize the forming parameters.Firstly,by setting the blank holding force as 807 kN,friction coefficient as 0.135,blank holder stroke as 205 mm,and forming force as 3572 kN,the drawing process of the rear floor was numerically simulated based on Autoform software.Secondly,full-field grid strain measurement technique was used to measure the actual drawing part,and full-field forming mar-gin cloud image,forming limit diagram and thinning cloud image were obtained.Finally,the forming parameters of the drawing process were optimized by adjusting the blank holding force,the depth and radius of the draw bead.The potential risk areas of the forming margin were obtained by simulation and the maximum thinning rate of the parts was 24.10%and the full-field forming margin was less than 10%.The measurement results showed that the maximum forming margin was-9.29%.After the die radius of the risk area was polished,the maximum forming margin reached-10.65%.After comprehensive analysis of the measurement results and simulation results,with the blank holding force as 782 kN,the radius of draw bead B as 4.5 mm and the depth of draw bead B as 4.5 mm,the part without cracking and wrinkling defects was obtained,and the maximum forming margin was-14.33%,which met the needs of large-scale production.The numerical simulation combined with the full-field grid strain measurement technology can guide the die repair operation and forming parameters optimization,which can improve the commissioning efficiency of die.

关 键 词：后地板拉延件 数值模拟 全场网格应变测量 成形裕度 拉延筋 

分 类 号：TG356[金属学及工艺—金属压力加工]