基于AUTOFORM软件的超高强钢前围板中间横梁零件工艺优化

Optimization of forming process for dash panel beam with ultra high strength steel based on AUTOFORM software

针对某车型超高强钢零件前围板中间横梁存在的成形起皱开裂、回弹过大以及边部付型问题,借助于有限元软件AUTOFORM对原工艺方案进行了全流程仿真,并对问题原因进行分析,提出了一种优化工艺方案,并采用AUTOFORM软件从成形、减薄、回弹等方面对新方案进行了评估。结果表明:优化后的工艺方案最大减薄率减小约4%,同时边部付型良好,基本与产品边界一致;零件上的最大回弹值为1.21 mm,较优化前减小1倍,且呈对称分布;同时,零件在端部法兰位置的起皱基本消失,并从零件实冲结果得以验证。提出的优化工艺方案能够保证零件成形的充分性,回弹得到改善,且一步成形到底的方式边部付型更好,解决了原方案存在的问题,该方法可用于指导其他超高强钢零件的应用。

For the problems of wrinkling,crack,large springback and edge compliance in the forming process of dash panel beam with UHSS（ ultra high strength） steel,a whole process simulation was performed by AUTOFORM software,and the problems were analyzed. Then,an optimum process was proposed and evaluated focusing on formability,thinning,springback. The results show that the maximum thinning rate decreases 4% lower than that of the original process,while the edge compliance is much closer to the part edge. The maximum springback is 1. 21 mm,nearly half smaller than before,and it is in symmetrical distribution. Meanwhile,the wrinkling at the end flange almost disappears,and it is verified by the actual stamping test. The optimum process ensures sufficient forming and decreases springback. Also,the edge compliance forms well by one-step forming to the end directly. This forming method has a guiding significance for the application of UHSS parts.