汽车后地板上横梁冲压工艺优化

Optimization of stamping process for automobile rear floor upper beam

某汽车后地板上横梁在拉延后,出现了严重的起皱缺陷。针对该问题,首先使用Auto Form软件模拟其拉延工序,分析起皱原因。由于拉延过程中板料中间的材料没有被充分拉延,导致在产品台阶圆角与侧壁交界处因剪应力造成起皱。其次,利用Auto Form软件对冲压工艺进行了优化。仿真实验结果表明,通过增大台阶面的过渡圆弧半径R可以减少起皱,当R值过大时,在后序翻边时会导致台阶边缘有开裂风险,当R为400 mm时,产品成形较好。最后,通过冲压试验验证该优化方案的有效性,起皱问题得到了有效控制,从而减少了模具开发成本,缩短了生产周期,保证了该产品按期交货。

For the problem of serious wrinkle after drawing of automobile rear floor upper beam,firstly,the drawing process was simulated by software AutoForm,and the cause of wrinkling was analyzed that during the drawing process,the material in the middle of sheet was not fully drawn,and wrinkles were formed at step fillet and sidewall junction zone of product due to shear stress.Next,the process optimi?zation was conducted by software AutoForm.The simulation results show that the wrinkle can be reduced by increasing the radius R of transitional arc in the step surface.However,the edge of step produces a risk of cracking if the R is too large during the subsequent flanging process,and the product is formed well when R is 400 mm.Finally,the effectiveness of the optimization plan was verified through the actual stamping test,and the wrinkle problem is effectively controlled to reduce die costs,shorten production cycles and ensure that the product is delivered on time.