汽车A柱加强件拉延成形稳健性分析及工艺参数优化

Robustness analysis on drawing and optimization on process parameters for automobile A-pillar reinforcement

基于Auto Form软件平台,采用Sigma模块与响应面相结合的方法,研究了某型汽车A柱加强件的成形工艺,解决了零件的成形缺陷。首先,根据零件形状设计工艺补充面并建立有限元模型,利用Sigma模块分析各工艺参数对零件成形质量的影响大小及规律,得到影响成形结果的主要因素及其取值范围。再基于响应面法,研究了分段式拉延筋阻力系数x1,x2,x3,x4和压边力x5等工艺参数对加强件的减薄率和成形性的影响规律,通过建立多目标优化模型得出最佳的成形工艺参数方案为：x1=0. 45、x2=0. 30、x3=0. 45、x4=0. 30、x5=100 k N。并使用优化工艺方案进行了试生产,发现试验结果与模拟结果基本一致,获得了表面质量好、形状误差小、尺寸精度高的零件。

Based on the software platform Auto Form,the forming process of A-pillar reinforcement for a certain type of automobile was studied by combining the Sigma module with the response face,and the forming defects of parts were solved. First,according to the shape of part,the process addendum surface was designed,and the finite element model was established. Then,the influences of process parameters on the forming quality of part were analyzed by Sigma module,and the main factors and value range influencing forming results were obtained. Based on the response surface method,the influences of process parameters such as the segmented drawbead resistance coefficient x1,x2,x3,x4 and the blank holder force x5 on the thinning rate and formability of reinforced parts were studied,and the optimum forming process parameters with x1= 0. 45,x2= 0. 30,x3= 0. 45,x4= 0. 30,x5= 100 k N were obtained by establishing a multi-objective optimization model. Furthermore,the actual production test was conducted by the optimized process parameters. The test results are basically consistent with the simulation results to get the parts with good surface quality,small shape error and high dimensional precision.