复杂轿车前底板变压边力数值模拟和物理模拟研究

Numerical and Physics Simulations of Variable Blank Holder Force in Process of Deep Drawing Complex Overlay

为了有效地解决实际生产中如何优化复杂轿车前底板拉深成形过程中的变压边力工艺,首先基于相似物理模拟理论建立了前底板的简化物理模拟模型,其次通过数值模拟手段从众多典型变压边力模式中得到一条最优化变压边力加载曲线,使拉深件不出现起皱和拉破现象,且厚度分布最均匀。最后通过实际物理模拟实验对比来验证所得结果。数值模拟和物理模拟最终结果均表明:U型变压边力加载模式是复杂轿车前底板拉深成形的较优压边力控制曲线,其状态下不仅拉深工件的厚度最大减薄率最小,而且工件的最终厚度变化率的整体均方差为最小。

In order to effectively solve the problem that how to optimize the technics of variable blank holder force （BHF） in the process of deep drawing complex automotive forward-soleplates in real manufacture, one simplified simulation model was built based on the Similitude-theory. Then numerical simulations were carried out to search out which one was the best from lots of typical variable BHF modes, with better uniformity in thickness distribution and without wrinkling and cracking phenomena. Finally, physics tests were done to validate above results. Both numerical simulation and physics simulation results show that under the control of U curve of variable BHF, not only the maximum thickness-reduction of workpiece is the lowest, but also the whole mean-squared error of thickness-reduction is the minimal.