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针对盒形冲压件成形过程中易出现破裂、起皱和回弹过大的问题,采用有限元分析软件DYNAFORM对顶部弧面、侧壁直边的磁体外盖进行拉延、切边和回弹过程模拟,分析制件成形规律;采用正交实验法模拟研究压边力、凹模圆角半径、模具间隙和冲压速度等工艺参数对制件冲压成形的影响。以制件的最大减薄率和回弹量为评价指标,采用极差和方差分析法对模拟结果进行分析表明,各工艺参数对评价指标的影响显著性,得到的最佳工艺参数优化组合为压边力120kN、凹模圆角半径3mm、模具间隙1.05t、冲压速度6m·s-1。采用优化工艺参数组合进行模拟和冲压实验,获得了较好的评价指标值,实验结果与模拟结果相吻合。
Aiming at the problem of easy fracture, wrinkling and rebound in the forming process of box-shaped stamping parts, the finite element analysis software DYNAFORM is used to draw, trim and rebound the magnet cover on the top arc and the straight side wall. Process simulation was used to analyze the rule of forming. The orthogonal experiment was used to simulate the influence of blank holder force, die fillet radius, die gap and stamping speed on the stamping of workpiece. Taking the maximum reduction rate and the rebound amount of the workpiece as the evaluation index, the analysis of the simulation results by the range and variance analysis shows that the influence of each process parameter on the evaluation index is significant. The optimal combination of the optimum process parameters is Binding force 120kN, die radius of 3mm, mold gap 1.05t, punching speed 6m · s-1. The simulation and stamping experiments were carried out with optimized process parameters, and the better evaluation indexes were obtained. The experimental results are consistent with the simulation results.