汽车覆盖件内外板合模开发成形风险防控  

Forming risk prevention of two-in-one die forming for internal and external plates of automotive panel

作　　者：曹彪 乔晓勇 申丹凤 覃策 李开文 Cao Biao;Qiao Xiaoyong;Shen Danfeng;Qin Ce;Li Kaiwen(Technology Department Centre,Saic-GM-Wuling Automobile Co.,Ltd.,Liuzhou 545007,China)

机构地区：[1]上汽通用五菱汽车股份有限公司技术中心,广西柳州545007

出　　处：《锻压技术》2024年第12期59-65,共7页Forging & Stamping Technology

基　　金：广西科技重大专项(桂科AA23062069)。

摘　　要：汽车覆盖件零件通过合模开发能大幅提高生产效率、降低模具开发成本和生产成本。以拉延深度差异大的车门外板和车门内板为研究对象,分析了零件在拉延前、拉延过程中以及拉延到底时3个阶段板料和凹凸模的相对位置以及受力状态,提出了零件合模开发时存在的两种潜在风险:对于拉延深度较浅的零件,板料受自重作用导致下塌,进而影响定位稳定性;内外板零件按照机床中心对称布置时,零件实际最大成形力与理论值存在较大偏差,导致零件成形不充分。并提出了对应的预防控制措施:通过在拉延深度较浅的凸模中增加托料机构来防止板料下塌现象;通过调整零件工艺中心与机床工作台中心的相对位置来缩小零件实际成形力与理论值的偏差,同时满足机床允许偏载要求。经过验证,板料放料下塌以及成形力偏差问题得到有效控制,取得了令人满意的效果,为其他同类型零件合模开发提供了参考。The development of automotive panel through two-in-one die forming can significantly improve production efficiency,reduce mold development costs and production costs.Therefore,for the inner and outer plates of automotive door with large differences in drawing depth,the relative positions and force states between blank and punch&die in three stages such as before drawing,drawing process,and drawing to the bottom were analyzed.Then,two potential risks in the drawing process were proposed,One risk was that for the part with shallow drawing depth,the plate would collapse due to its own weight,which affected the positioning stability,and the other risk was that when the inner and outer plates were arranged symmetrically according to center of machine,there was a large deviation between the actual maximum forming force of part and the theoretical value,resulting in insufficient forming of the part.And the corresponding preventive and control measures were provided.The collapse of sheet metal was prevented by adding a material support mechanism in the punch with shallow drawing depth,and by adjusting the relative position between the process center of part and the center of machine worktable to reduce the deviation between the actual and theoretical forming force values and meet the requirement of allowable unbalance load of the machine.After verification,the results show that the problems of sheet metal collapse and forming force deviation are effectively controlled,achieving satisfactory results and providing reference for two-in-one die development.

关 键 词：汽车覆盖件 合模开发 不等深拉延 成形力偏差 力矩平衡 

分 类 号：TG385.2[金属学及工艺—金属压力加工]