基于响应面法的台阶式凸模冲裁工艺参数优化

Parameters optimization of step-shaped-punch blanking based on response surface methodology

采用台阶式凸模冲裁,可有效提高6061铝合金板的冲裁断面质量。为建立冲裁速度、冲裁间隙、凸模圆角半径、凸台高度、凸台宽度对光洁率和塌角率的影响模型,通过2水平析因试验设计和有限元仿真相结合的方法对设计变量进行显著性筛选,对筛选后的设计变量采用Box-Behnken试验设计和有限元仿真,建立光洁率和塌角率的响应面模型,并进行方差分析,结合遗传算法对响应面模型进行修正,求解上述模型确定最佳的工艺参数并进行仿真验证。修正后响应面模型的预测值与试验结果误差较小,为工艺参数的确定提供了有效的方法。

The cutting-surface quality of sheet 6061 aluminum alloy can be effectively improved by means of step-shaped-punch blanking. To analyze the effects of the cutting speed, blanking clearance, punch radius, punch step height and punch step width on clean-cutting rate and die-roll rate, the relatively important factors were obtained by combining 2-level factorial design with fi- nite element analyses （FEA）, the response surface models of clean-cutting rate and die-roll rate were built based on Box-Behnken Design of Experiments approach along with FEA, which include the important process parameters an analysis of variance （ANO VA） test was carried out, the response surface models were optimized using a genetic algorithm （GA）, the optimum process parameters were worked out by computing the optimum solutions of the above models, and the simulation approach was employed to verify the optimum process parameters. The results show that there is significant agreement between the modified models and FEA, and this method provides a valid way to develop the optimum process parameters.