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以某型号微型面包车的前地板拉延成形过程为例,对材料特性进行分析,并建立数学建模后,进行冲压模拟分析。选取冲压成形工艺参数中的压边力、凸凹模间隙和拉延筋高度3个因数进行正交试验分析,以坯料的局部最小厚度为优化目标值,以防止产生拉裂现象。冲压数值模拟分析表明,压边力最显著,拉延筋高度为其次,凸凹模间隙为最次。为保证前地板冲压成形的均匀性,最佳工艺参数为压边力950 k N、凸凹模间隙0.84 mm、拉延筋高度6 mm,并对前地板零件进行验证。验证结果表明,成形表面较为光顺,且无裂纹,虽在曲率变化较大的区域有少量褶皱外,但冲压质量完全符合前地板设计要求。
Taking the drawing process of the front floor of a minivan as an example, the material properties were analyzed, and the mathematical modeling was established, then the stamping simulation was carried out. The factors of blank holder force, punch-gap clearance and drawbead height in the process parameters of press forming were selected to carry out orthogonal test and analysis. The local minimum thickness of blank was taken as the optimized target to prevent the occurrence of cracking. Stamping numerical simulation shows that the most significant blank holder force, drawbead height followed, the punch and die gap for the first time. In order to ensure the uniformity of the former stamping, the best process parameters are the blank holder force of 950 kN, the clearance of punch and die of 0.84 mm, the height of drawbead of 6 mm, and the verification of the front floor parts. The verification results show that the forming surface is smooth and free of cracks. Although there is a few wrinkles in the area with large curvature, the stamping quality fully conforms to the design requirements of the front floor.