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相较于传统无铆连接,平底无铆连接的主要优势在于通过模具参数设计,避免接头在连接过程中形成凸起,保证接头一侧光滑平整,扩大其在汽车轻量化中的应用。平底无铆连接模具的几何参数主要包括冲头圆角、冲头拔模斜度、压边圈内半径、压边圈圆角和冲压速度。采用正交试验的方法优化了连接模具的几何参数,并通过试验连接板材Al5052对正交试验的结果进行验证。研究结果表明:冲头圆角对互锁值的影响最大,压边圈内半径次之,其次分别是冲头速度、拔模斜度和压边圈圆角半径。在优化的连接模具组合下,对有限元分析和试验结果进行了对比,互锁值的误差为6.1%,颈厚值的误差为8.2%,表明了利用正交试验得到的连接模具可以精确预测平底无铆连接成形过程。
Compared with the traditional non-riveting connection, the main advantage of the flat riveting-free connection is that the design of the die parameter avoids the bulge of the joint during the connection, ensures the smoothness of the joint and enlarges its application in the light weight of the automobile. Flat without riveting connection of the geometric parameters of the mold include the punch fillet, punch taper, blank holder radius, blank holder fillet and punching speed. Orthogonal experiments were used to optimize the geometrical parameters of the connection mold and the results of the orthogonal test were verified by testing the Al5052 plate. The results show that the impact of the punch angle on the interlocking value is the greatest, the radius of the blank holder is the second, followed by the punch speed, the draft and the fillet radius respectively. Under the optimized connection mold combination, the finite element analysis and test results were compared, the error of interlocking value was 6.1% and the error of neck thickness was 8.2%, which showed that the connecting mold obtained by orthogonal experiment can accurately predict Flat without riveting connection forming process.