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以某汽车前门加强板三维立体模型简化件为研究对象,依托CAE分析软件Dynaform建立板料冲压成形有限元模型并进行数值模拟分析。将正交试验方法与数值模拟结果有机结合,选取冲压过程中压边力、摩擦系数、模具间隙和冲压速度4个工艺参数作为正交试验中的考察因素,每个因素选取3个水平值,以板料成形后的最小厚度为成形优劣指标,分析不同因素的不同水平对数值模拟结果和成形质量的影响。结果表明,对冲压件最小厚度影响程度从大到小依次为:摩擦系数>压边力>冲压速度>模具间隙,最佳工艺参数组合为压边力300 k N、冲压速度1000 mm·s-1、摩擦系数0.10和模具间隙1.35 mm,并通过试验验证其正确性及实用性。
Taking a simplified model of a three-dimensional model of a car’s front door stiffener as the research object, a finite element model of sheet metal forming by means of CAE analysis software Dynaform was established and numerical simulation was carried out. The orthogonal test method and numerical simulation results are combined organically. The four process parameters of blank holder force, friction coefficient, die clearance and punching speed are selected as the investigation factors in the orthogonal test. Three factors are selected for each factor, The minimum thickness of the sheet metal after forming is the index of the forming quality, and the influence of different factors on the numerical simulation results and the forming quality is analyzed. The results show that the influence of the minimum thickness on the stamping parts is as follows: friction coefficient> blank holder force> stamping speed> die clearance. The optimum process parameters are the blank holder force of 300 kN and the stamping speed of 1000 mm · s- 1, friction coefficient of 0.10 and die clearance of 1.35 mm, and through the test to verify its correctness and practicability.