前车门外板工艺分析及工序数量优化方法

Process analysis and optimization method of operation quantity for automobile front door outer panel

对汽车前门外板工序数量优化方法进行了研究,利用CAE分析软件AutoForm建立CAE分析模型,进行冲压工艺仿真模拟分析,经过多次优化分析得到最优结果。分析结果表明,水切侧减薄率过高,易产生开裂风险,需增加整形工序进行应对,从而有效地解决前门外板成形性问题。后视镜安装孔位于前门外板上,为避免翻边与侧冲孔工序干涉问题,工艺规划需5道工序完成。通过合理的工艺优化和模具结构设计,采用切整工艺和穿刀块侧冲孔模具结构,有效地减少了工序数量,由5序降为3序。利用最少工序生产制造出质量和精度合格的产品,实现了模具降本,降低了产品开发成本和周期。

The optimization method of operation quantity for automobile front door outer panel was studied,and the CAE analysis model was established by software AutoForm.Then,the stamping process was simulated and analyzed,and the optimized result was obtained by the multiple optimization analysis.The analysis results show that the thinning ratio in the water cut side is so high that it is easy to generate cracking risk,and the sizing process is added to solve the formability problem effectively of the front door outer panel.Furthermore,the fixing hole of rear view mirror is located on the front door outer panel,and the process plan requires five steps to avoid interference between flanging and side piercing operations.Therefore,through reasonable process optimization and die structure design,the operation quantity is effectively reduced from five to three by the cutting and sizing process and the die structure with side piercing through block,and the qualified products of quality and precision are produced by the least operation quantity to reduce the cost of die as well as the cost and cycle of product development.