保险杠立柱成形回弹分析及其控制

Analysis and control of springback in forming the pillar of bumper

保险杠立柱是重要的结构件,对汽车安全性能方面起着重要的作用。该零件为U形件,材料为高强度钢板,在弯曲成形后会产生回弹现象,回弹的产生将影响零件的尺寸精度和后续的焊装质量。文章首先对保险杠立柱的成形方案进行确定,并利用eta/DYNAFORM对成形过程及回弹过程进行模拟仿真,模拟过程采用分两步计算的dynain方法,分析了摩擦系数、模具间隙等工艺参数对回弹量的影响规律,同时采用模具型面补偿法控制回弹。文章还根据所优化的工艺参数和模具型面对各工序模具进行设计,并通过实际生产得到了合格的零件,验证了工艺方案的合理性和数值模拟的准确性。

The pillar of bumper is a structure part and plays an important role in safety aspect. It is U-shaped part and the material used is high strength steel, so springback would occur after bending which would affect the dimensional precision and the quality of welding and assembly at the following processes. In this paper the forming scheme of the pillar of bumper was determined firstly and then the forming and springback processes were studied by using the FEM simulation software Dynaform. The simulations were done by the two-steps Dynain method and the effects of friction coefficient, gap of tools on the springback were analyzed. The die surface compensation method used to control the springback of the pillar of bumper was studied. Finally, the dies were designed and eligible parts had been obtained by adopting the optimized parameters and die surface. It proves that the forming scheme is reasonable and the results of simulation are correct.