轿车后地板成形工艺及修边冲孔模具设计  

Forming process and trimming-Dlpunching die design of car rear floor

作　　者：万志远 Wan Zhiyuan(Academy of Mechanical Engineering,Shandong Huayu University of Technology,Dezhou 253034,China)

机构地区：[1]山东华宇工学院机械工程学院,山东德州253034

出　　处：《锻压技术》2024年第2期71-76,共6页Forging & Stamping Technology

基　　金：山东华宇工学院校级协同创新中心“智能装备技术研发协同创新中心”项目。

摘　　要：针对轿车后地板成形材料薄、易产生回弹和易起皱等问题,分析了后地板零件的结构特点,发现其成形深度大,存在一个特有的“凹坑”且冲孔数量多。基于该结构特点设计工艺补充,确定了先成形“凹坑”的两次成形、修边冲孔和翻边冲孔工艺方案,并采用Dynaform软件对成形过程进行了模拟,确定了最优压边力为425 kN,此时零件的最大厚度减薄率为24.489%,周围起皱区域的材料增厚率基本在10%以内。提出在修边冲孔工序中增加14把废料刀块,使废料呈“两边分”的流向方式,并设计了废料刀与上下模刃口尺寸。最后,基于成形工艺,设计了后地板修边冲孔模具,并进行试模冲压,得到每道工序压制的零件,并与成形工艺进行了对比。实验结果表明:工艺设计合理,模具设计正确,可以冲压出合格的产品,符合工厂实际要求。Aiming at the problems such as thin forming material,easy to have springback and wrinkles of car rear floor,the structural characteristics of rear floor part were analyzed,and it was found that its forming depth was large,and there were a unique"pit"and a large number of punching holes.Then,based on the structural characteristics,the process supplement was designed,and a process scheme was determined to form the"pit"first by two-stage forming and then trimming-punching and flanging-punching.Furthermore,the forming process was simulated by software Dynaform,and the optimal blank holder force was determined to be 425 kN with the maximum thickness thinning rate of 24.489%for part and the material thickening rate in the surrounding wrinkled areas within 10%.In addition,fourteen scrap cutter blocks were proposed to add in the trimming and punching process to make the waste flow in a"two-sided"direction mode,and the scrap cutter and the upper and lower die edge dimensions were designed.Finally,based on the forming process,a real floor trimming-punching die was designed,the trial stamping was performed to obtain the parts in each process,and the forming process was com-pared.The results show that the process design is reasonable,and the die design is correct.Thus,the qualified products can be produced to meet the the actual requirements of factory.

关 键 词：后地板 拉延成形 废料刀块 修边冲孔 翻边冲孔 模具设计 

分 类 号：TG386[金属学及工艺—金属压力加工]