中厚板轿车摇臂件拉深成形有限元模拟分析

Finite element analysis of deep-drawn engine rocker of car with middle-thick plate

将厚向异性屈服函数、单元级双面接触算法的能够反映强烈弯曲效应的Mindlin曲壳单元模型引入动力显式中心差分格式的有限元算法,建立对复杂形状的中厚板件拉深成形有限元模拟分析算法;在此基础上,以轿车摇臂厚板金件为例,分析了材料厚向异性参数r值、凹模圆角以及压边力大小对此类成形件成形性的影响。通过数值模拟与实际拉深成形实验的对比,验证了本文方法的有效性;同时,结合实验研究了此类单元对工具弯曲圆角大小的适应性。

The Hill's 1979 yield function with thickness anisotropy and Mindlin shell element with double-surface contact algorithm at element level, which can reflect strong bending effects and changing gaps between die and punch, are introduced into the dynamic explicit FEM formulation. The proposal method is suitable for the deep drawing process simulation of middle thick sheet metal with complex shape. To verify the method, the deep-drawing processes of a car's rocker are numerically simulated, in which the influence of normal anisotropic parameter r, die corner radius and binder-force on formability of the sheet is studied. Comparison between numerical and experimental results shows the validity of the present simulating scheme. Besides, based on experimental results, the adaptability of present element model on size of the die-corner in tools is also analyzed.