双层不锈钢消声器壳体冲压工艺CAE分析与优化

CAE simulation and optimization of double-layer stainless steel muffler shell stamping process

针对SUS304双层不锈钢异型消声器壳体成形困难的现状，提出了采用不同形状坯料通过3次拉深工序来成形的工艺规划，重点采用正交试验和数值模拟分析方法在hypermesh中对第一次成形工艺参数进行了优化。坯料形状、压边力、拉深筋和双层板间的摩擦系数分别分为4个不同水平，以每一次拉深结束后坯料的最大减薄率和增厚率作为衡量坯料开裂和起皱的指标。对正交试验的数据进行分析，得到了4种因素和4种水平下的拉深指标，最佳工艺参数为坯料形状为BL4，压边力为350kN、拉深筋分布为DB3及双层不锈钢板之间摩擦系数为0.2。采用最佳工艺参数的模拟结果都在安全范围之内，为实际生产提供了指导。

Aiming at the difficulties of SUS304 double-layer stainless steel forming of the special-shaped muffler, the process planning of three drawing processes for different shape blanks was put forward, orthogonal experiment and numerical simulation analysis method were used to optimize the first-order drawing process parameters in hypermesh. Blank shape, blank holder force, drawbead and friction coeffi- cient between the double plates were divided into four different levels respectively, the maximum thinning rate and maximum thickening rate of each deep drawing blank were set as the index of blank crack and wrinkle. By analyzing the data of orthogonal experiment, the draw indexes under four elements and four levels were obtanined, and it is concluded that the best process parameters for the blank shape is B/A, the blank-holder force is 350 kN, the distribution of drawbead is DB3 and the friction coefficient between double stainless steel plates is 0. 2. The simulation results of the best process parameters are all in the safe range and provide guidance for actual production.