基于星点设计和响应面法的支架焊合件成形工艺优化  

Optimization of forming process for bracket welded parts based on star point design and response surface method

作　　者：滕士意 王匀[1] 魏熹鸣 杜道忠 TENG Shi-yi;WANG Yun;WEI Xi-ming;DU Dao-zhong(School of Mechanical Engineering,Jiangsu University,Zhenjiang 212013,China;School of Public Utility,Jiangsu Urban Rural Construction Vocational College,Changzhou 213000,China)

机构地区：[1]江苏大学机械工程学院,江苏镇江212013 [2]江苏城乡建设职业学院公用事业学院,江苏常州213000

出　　处：《塑性工程学报》2024年第3期50-59,共10页Journal of Plasticity Engineering

基　　金：国家自然科学基金资助项目(51575245;51679112);无锡市科技攻关项目(G20222007)。

摘　　要：通过对焊合件的材料、结构及工艺进行分析,确定关键影响工序。对原冲压工艺方案进行多工序仿真模拟,并分析仿真结果,找寻产生开裂缺陷的原因。通过增加焊合件预成形设计和改变坯料的形状来改善工序间的载荷传递,建立以焊合件的最大减薄率和最大回弹量为优化目标,以冲压速度、摩擦因数、压边力和模具间隙为设计变量的响应面模型,结合二阶响应面法与DesignExpert,采用星点设计试验方法对支架焊合件的工艺参数进行优化,确定最佳参数组合为:冲压速度1263mm·s^(-1)、摩擦因数0.15、压边力598k N、模具间隙4.55mm。试产结果表明:通过预成形方案与优化工艺参数可以解决支架焊合件开裂及回弹问题。The materials,structures and processes of welded parts were analyzed to determine the key influencing processes.The multiple process simulation of original stamping process plan was carried out,the simulation results were analyzed,and the reason of cracking defects was identified.The load transfer between processes was improved by increasing the preforming design of welded parts and changing the shape of billet,the response surface model was established with the maximum thinning rate and the maximum springback of the welded parts as optimization objectives,and the stamping speed,friction factor,blank holding force and mold clearance as design variables.Combining second-order response surface method and Design Expert,the central composite design experimental method was used to optimize the process parameters of the bracket welded parts.The determined optimal parameters are stamping speed of 1263 mm,friction factor of 0.15,blank holding force of 598 kN,mold clearance of 4.55 mm.The results of trial production show that the cracking and springback problems can be solved by preforming scheme and optimizing process parameters.

关 键 词：支架焊合件 冲压成形 BR440高扩孔钢 预成形 星点设计 响应面法 

分 类 号：TG386[金属学及工艺—金属压力加工]