铝合金前盖内板成形优化与尺寸控制

Formability Optimization and Springback Control of Aluminum Inner Engine Hood

受政策与市场双重影响,新能源汽车已成为未来汽车行业的发展趋势,使用铝合金代替钢板进行车身制造,可显著减轻整车重量,提升汽车续航里程。铝合金冲压成形性能较差,尺寸回弹难以控制,在模具设计阶段,需要借助冲压数值模拟手段对工艺方案进行仿真优化。文章以某车型前盖内板为例,介绍了铝合金前盖内板冲压数值模拟、成形性优化与回弹补偿设计等相关内容,并结合实际零件测量结果,对冲压模拟准确性及补偿方案有效性进行了验证。分析结果表明,采用Banabic-BBC2005材料屈服准则以及Swift/Hockett-Sherby加工硬化准则对成形过程进行数值模拟,其成形性与回弹模拟结果具有较高的准确性与可信度;铝合金板料对工艺参数及产品造型设计要求较高,需要根据冲压模拟结果进行相应优化;通过型面补偿方法可有效改善零件回弹,缩短模具更改调试周期。

Influenced by the dual effects of policy and market,new energy vehicles have become the development tendency of the future automobile industry.The weight can be reduced and the mileage of the vehicle can be enhanced significantly by the use of aluminum alloy instead of steel for body manufacturing.It is necessary to simulate and optimize the formability and springback in the early stage of model design,since the formability performance of aluminum alloys is poor and the springback is hard to control.In this paper,the inner engine hood is taken for example,the simulation and optimization process of formability,the simulation and compensation of springback are introduced,then the accuracy of simulation is verified with the help of simplified stamping tools and other instruments.The result proves that the material model with Banabic-BBC2005 yield criterion and Swift/Hockett-Sherby hardening criterion shows high accuracy in formability and springback simulation.Aluminum alloys put forward higher requirements for product and die design,which should be optimize according to the simulation.The die face compensation reduces the springback of aluminum parts effectively,which will shorten the die test cycle.