半截式行李箱外板波纹缺陷分析及工艺优化

Ripple defect analysis and process optimization on half-cut trunk

通过对某车型半截式行李箱外板模具开发中遇到的钣金缺陷问题分析,揭示了材料成形中的某些基本规律。鉴于CAE在该问题分析上存在不足,采用塑性力学、工艺学和CAE相结合的方法,探索产生波纹缺陷的根本原因,分析表明,冲压方向上的弦高投影过大是产生变形的根源,而加工硬化是克服变形的难点。借鉴理论分析的结论,制定出有针对性的优化方案,不仅消除了波纹缺陷,还提高了材料利用率。优化后的工艺方案在新项目中得到了成功验证,零件材料利用率提升11%,单件成本降低7.93元。

By analyzing the apprearance defect of the half-cut trunk during die development, some rules of material forming were revealed. Because of the insufficient analysis of CAE, the root cause of ripple defect was explored by combining methods of plasticity mechanics, technology and CAE. The results show that the overlarge projection of the string height in the stamping direction is the source of deforma- tion, and the difficulty for overcoming the deformation is work hardening. A targeted rectification plan is formulated by theoretical analy- sis, which not only eliminates the defect but also improves the utilization of material. Thus, the process optimization scheme is successful- ly verified in new projects, and the material utilization increases by 11% and the cost of the single part is reduced by RMB 7.93.