汽车前车门加强板冲压工艺设计及成形优化  

Stamping process design and forming optimization of automobile front door stiffener plate

作　　者：万志远 倪传东 WAN Zhi-yuan;NI Chuan-dong(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：《塑性工程学报》2024年第7期71-77,共7页Journal of Plasticity Engineering

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：针对汽车前车门加强板变形复杂、材料流动不易控制、成形开裂等问题,首先分析了汽车前车门加强板结构特点,确定了“一模两件”的总体成形方案,并详细设计了拉延成形、修边-冲孔-整形、修边-侧冲和侧修边-侧冲孔-冲孔-切断的成形过程。其次以材料减薄率为切入点,采用数值模拟探究了压边力、模具间隙和冲压速率对零件成形质量的影响规律,预测了零件开裂的位置和程度,得到了较为优异的工艺参数:压边力控制在400 kN以内,模具间隙不小于1.10 mm,冲压速率不高于3000 mm·s^(-1)。最后采用正交试验方法,得到了各因素各水平最大减薄率平均值,计算出压边力、模具间隙和冲压速率这三者的极差分别为3.223%、1.489%和0.763%。基于分析结果得到了压边力300 kN,模具间隙1.15 mm,冲压速率3000 mm·s^(-1)的最优工艺参数组合,并进行了生产试验验证,制出了合格成形零件实物。In view of the complex deformation,difficult control of material flow,forming cracking and other problems of the automobile front door stiffener plate,firstly,the structural characteristics of the automobile front door stiffener plate were analyzed,and the overall forming scheme of“one die and two pieces”was determined,and the forming processes of drawing forming,trimming-punching-shaping,trimming-side punching and side trimming-side punching-punching-cutting were designed in detail.Secondly,taking the material thinning rate as the starting point,numerical simulation was used to explore the influence laws of blank holder force,die clearance and stamping velocity on the forming quality of parts,and the position and degree of cracking for parts were predicted.The better process parameters were obtained:the blank holder force is controlled within 400 kN,the die clearance is not less than 1.10 mm,and the stamping velocity is not higher than 3000 mm·s^(-1).Finally,the orthogonal test method was used to obtain the average values of the maximum thinning rate of each factor at each level,and the ranges of blank holder force,die clearance and stamping velocity are calculated to be 3.223%,1.489%and 0.763%,respectively.Based on the analysis results,the optimal process parameter combination of blank holder force of 300 kN,die clearance of 1.15 mm and stamping velocity of 3000 mm·s^(-1) was obtained,and the production test verification was carried out and qualified formed parts were produced.

关 键 词：前车门加强板 工艺设计 最大减薄率 拉深模 正交试验 

分 类 号：TG386[金属学及工艺—金属压力加工]