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针对弯曲件汽车车窗升降板在成形过程中因板料弹性回复和残余应力的存在易产生回弹而影响零件尺寸和装配性能的问题,借用Dynaform平台对板料弯曲成形过程进行数值模拟及回弹预测。针对板料厚度A、冲压速度B、摩擦因数C和模具间隙D等4项影响因素设计9组不同的成形工艺参数组合,分别对板料进行正交试验和重复正交试验(重复次数S=3)获取回弹结果,并采用极差分析法(方案1)和方差分析法(方案2)进行影响因素的主次排序和工艺优化。方案1和方案2分别获得的影响因素主次顺序和优化工艺参数组合为A>B>D>C,A_2B_2D_3C_2和B>D>C>A,B_2D_3C_2A_1。将两组工艺参数进行对比验证,进而确定最佳参数组合为板料厚度A=0.9 mm,冲压速度B=5000 mm·s~(-1),摩擦因数C=0.125,模具间隙D=1.15。利用该工艺进行试生产,检测零件危险圆角处厚度为t=0.70 mm,减薄率低于25%。经过试装配证明,采用优化后工艺参数成形的零件能够满足其使用条件下的尺寸和装配要求。
Aiming at the problem that the bending of automobile window lifter plate is easy to generate rebound due to elastic recovery and residual stress in the process of forming, which affects the size and assembly performance of the part, the Dynaform platform is used to simulate and reverse the sheet bending process Bomb prediction. Nine different forming process parameters were designed according to four influencing factors of sheet thickness A, punching speed B, friction coefficient C and die gap D. The orthogonal experiment and the repeated orthogonal experiment were carried out respectively (the number of repetitions S = 3) Obtaining the springback results, and using the range analysis (Option 1) and analysis of variance (Option 2) to make the primary and secondary influencing factors and process optimization. The main order of the influencing factors and the optimized process parameters obtained in the solutions 1 and 2 are A> B> D> C, A_2B_2D_3C_2 and B> D> C> A and B_2D_3C_2A_1 respectively. The two groups of process parameters were compared and verified, and then the best combination of parameters was determined as plate thickness A = 0.9 mm, punching speed B = 5000 mm · s -1, friction coefficient C = 0.125 and die clearance D = 1.15. The use of the process of pilot production, testing parts dangerous corner thickness of t = 0.70 mm, thinning rate of less than 25%. After the test assembly proved that the use of optimized process parameters formed parts to meet the conditions of their use of the size and assembly requirements.