铝合金双锐棱翼子板成形工艺优化  

Optimization of forming process for double-sharp-edged aluminum alloy fender

作　　者：蒋磊 龚熙 陈一哲 谢晖[3] 廖敏 陈俊伟 JIANG Lei;GONG Xi;CHEN Yi-zhe;XIE Hui;LIAO Min;CHEN Jun-wei(New Model Center,Dongfeng Honda Automobile Co.,Ltd.,Wuhan 430056,China;Hubei Key Laboratory of Modern Auto Parts Technology,Wuhan University of Technology,Wuhan 430070,China;The State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body,Hunan University,Changsha 410082,China)

机构地区：[1]东风本田汽车有限公司新车型中心,湖北武汉430056 [2]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 [3]湖南大学汽车车身先进设计制造国家重点实验室,湖南长沙410082

出　　处：《塑性工程学报》2023年第12期69-78,共10页Journal of Plasticity Engineering

基　　金：中国汽车产业创新发展联合基金资助项目(U1564202);湖南省创新型省份建设专项项目(2019GK5018)。

摘　　要：为了实现双锐棱造型在铝合金汽车覆盖件上的应用,以采用6系铝合金材料的某汽车翼子板为研究对象,对其主、副棱线均进行锐利化设计。针对棱线拉延易开裂、滑移线难以控制等问题,基于AutoForm软件建立了铝合金双锐棱翼子板拉延成形仿真模型。以主棱线最大减薄率和最大滑移量作为评价指标,选取压边力F、进料侧拉延筋阻力系数f_(1)、摩擦因数μ、出料侧拉延筋阻力系数f_(2)作为正交试验因素,利用极差分析和综合评分法获得铝合金双锐棱翼子板最优工艺参数组合为:f_(1)=0.2,F=1200 kN,f_(2)=0.3,μ=0.13。将优化后的工艺参数用于仿真求解,得出主棱线减薄率为15.3%,滑移量为2.162 mm,满足工程阶段仿真判断标准。最后在此基础上进行试模验证,获得了成形质量良好、主棱线无开裂及明显滑移线的合格样件。结果表明,基于有限元分析与数理统计的多指标综合优化求解可以实现双锐棱造型在铝合金汽车覆盖件上的成功应用。To realize the application of double-sharp-edged style on aluminum alloy automobile coverings,a certain automobile fender using 6 series aluminum alloy materials was used as the research object,and the main and secondary edges were sharpened.Aiming at the problems of easy cracking in drawing and difficult control of skid line,the simulation model of drawing forming of double-sharp-edged aluminum alloy fender was established based on AutoForm software.Taking the maximum drawing thinning rate and the maximum skid line width of the main edge as the evaluation indexes,the blank holder force F,the feeding side drawbead force coefficient f_(1),the friction factorμand the discharge side drawbead coefficient f_(2)were selected as the factors of the orthogonal test,and the optimal combination of process parameters of the double-sharp-edged aluminum alloy fender was obtained by using range analysis and comprehensive scoring method:f_(1)=0.2,F=1200 kN,f_(2)=0.3,μ=0.13.Using the optimized process parameters for simulation solving,the thinning rate and skid line width of the main edge were 15.3%and 2.162 mm,respectively,which meet the simulation judgment criteria during the engineering stage.Finally,the die trial verification was carried out on this basis,and the qualified samples with good forming quality,no cracking and obvious skid line of main edge were obtained.The results show that the multi-index comprehensive optimization solution based on finite element analysis and mathematical statistics can realize the successful application of double-sharp-edge style on aluminum alloy automobile coverings.

关 键 词：铝合金双锐棱翼子板 减薄率 滑移线 正交试验 综合评分法 

分 类 号：U466[机械工程—车辆工程] TG386[交通运输工程—载运工具运用工程]