基于响应面的封头冲压成形工艺多目标优化

Multi-objective optimization of stamping forming process of head based on response surface model

针对某封头加工厂在生产某型号封头零件时出现的起皱鼓包、厚度分布不均匀以及回弹变形严重的缺陷,提出一种新型的优化成形工艺方案。以减少起皱及鼓包现象、增大厚度均匀区、减小回弹变形量为优化目标,并以凸凹模间隙、凹模圆角半径、拉延筋高度以及拉延筋相对位置为优化因素,采用Matlab与Design-Expert软件相结合的方式进行响应面(RSM)拟合建模分析,得到3个目标量的二阶响应面模型,并验证了所建立的响应面模型的准确性,其误差范围小于7.4%,可用于后续优化。生产实践结果表明通过多目标优化后的封头成形工艺可以获得表面质量好、形状误差小、尺寸精度高的产品。

In the forming process of heads the defects of wrinkling,swelling,nonuniformity of the thickness,and springback deformation occurred in a certain factory.To solve these problems,optimized scheme is proposed.The objectives of this scheme are reducing the swelling,enlarging the region of uniform thickness,and decreasing the springback deformation.The optimizing factors include the clearance between the punch and die,the matrix radius,the height of drawbead and the relative position of the drawbead.The combination of software of Matlab and Design-Expert was adopted to conduct fitting and modeling analysis of the Response Surface Model（RSM）.A secondorder RSM with three objective values was obtained.The accuracy of the obtained RSM was verified and the error margin was less than 7.4%,which was available for subsequent optimizations.The actual production results show that heads with good surface finish,small shape error and high dimension precision can be produced by the application of the proposed multi-objective optimization scheme of forming process.