汽车座椅外侧板单动拉延成形工艺分析及优化

Process analysis and optimization on single drawing for outer panel of automobile seat

以某型号汽车座椅外侧板为例,采用Auto Form软件对座椅外侧板拉延成形过程进行模拟分析,并根据分析结果预测出拉延过程中的拉裂风险。通过调整零件的圆角半径和修改局部结构,消除了开裂风险,降低了最大减薄率。为取得更好的成形效果,选取压边力、摩擦系数、冲压速度、凸凹模间隙4个重要成形工艺参数进行正交试验及参数优化,得出最优工艺方案为:压边力250 k N、摩擦系数0.13、冲压速度1000 mm·s-1和凸凹模间隙2.42 mm,最终零件的最大减薄率为24.33%,最大增厚率为6.54%。采用优化后方案进行实际拉深试模,得出零件的成形性能与有限元模拟结果一致,工件质量完全符合设计要求。

For the outer panel of automobile seat in a certain car, its deep drawing process was simulated by AutoForm software, and the cracking risk was predicted in the drawing process. Then, the cracking risk was eliminated and the maximum thinning rate was also reduced by adjusting the radius of parts and modifying the local structure. In order to obtain a better forming effect, the blank holder force, friction coefficient, stamping speed and clearance between punch and die were chosen as process parameters, and the orthogonal experiment was carried out to optimize the above process parameters. The simulation results show that the optimal deep drawing process parameters are blank holder force of 250 kN, stamping speed of 1000 mm·s^-1, friction coefficient of 0. 13 and the clearance between punch and die of 2. 42 mm, with the max thinning rate of 24. 33% and the max thickening rate of 6. 54% obtained. Finally, the actual drawing test is conducted based on the simulation and orthogonal optimization. The forming property is in consistent with the finite element modeling results, and the part quality is completely satisfied with the design requirements.