变厚板汽车顶盖横梁成形工艺研究及模具设计

Research on forming process of a roof crossbeam based on variable-thickness rolled blanks and the die design

以某车型顶盖横梁为例,对变厚板的成形工艺分析方法进行了研究,通过充分结合Autoform建模计算效率高的特点和Dynaform在计算精度方面的优势,对变厚板顶盖横梁的成形性进行了探索;针对变厚板模具零件型面加工难度大的问题,提出采用型面分区偏置的方法处理加工依据,同时也对变厚板在板料成形过程中间隙控制和板料定位控制方面的方法进行了研究,完成了变厚板顶盖横梁模具设计,并试制成功变厚板顶盖横梁零件,验证了变厚板成形工艺及模具设计方法的有效性。

Taking the roof crossbeam of an automotive as an example, the forming process of the variable-thickness rolled blanks （VRB） was researched through combining the advan- tages of Autoform and Dynaform. To solve the difficulties in machining the VRB die sur- face, the divided-area offset method to constructing the machining CAD data was proposed. And the methods of controlling the gap and blank position were carried out to finish the die design of VRB roof crossbeam. Finally, the prototype of the VRB roof crossbeam was accomplished. The results showed that the forming process of VRB and the forming die de- sign method were correct.