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为提高覆盖件成形模拟效率,采用特征分析、数值模拟与正交试验相结合的研究方法对某车门内板成形工艺和工艺参数敏感性进行了研究。特征分析的结果表明:窗框转角及凹槽处易裂,零件转角处易皱,门内板窗框合边面刚性差。通过对工艺进行模拟调整,成形性能得到了改善。正交试验得到部分工艺因素的敏感性排序,敏感性从高到低为:凹模圆角半径,拉深筋高度,摩擦系数,坯料尺寸,压边力,凸凹模间隙。研究结果表明:基于对产品的特征分析,结合关键工艺参数的敏感性关系对板料成形过程进行模拟优化是合理制订汽车覆盖件成形工艺的有效途径。
In order to improve the simulation efficiency of the forming of the cover, the sensitivity of the forming process and the process parameters of a door panel was studied by means of a combination of characteristic analysis, numerical simulation and orthogonal test. The results of the characteristic analysis show that the corner of the window frame and the groove are easy to crack, the corner of the part is easy to wrinkle, and the rigidity of the edge of the window sash of the door inner panel is poor. Through the process of simulation adjustment, forming performance has been improved. Orthogonal test to obtain some of the sensitivity of the process factor order, the sensitivity from high to low: die radius, drawbead height, friction coefficient, blank size, blank holder force, punch die gap. The results show that the simulation and optimization of the sheet metal forming process based on the characteristic analysis of the product and the sensitivity of the key process parameters is an effective way to rationally formulate the automobile panel forming process.