某汽车车门内板拉延成形刺破工艺刀具结构参数优化

Optimization of Tool Structural Parameters of Lancing Process in Drawing Forming of An Automobile Inner Door

在某汽车车门内板拉延成形工序中引入了刺破工艺。基于数值模拟结果,采用响应面法对刺破刀具结构参数进行了优化,获得了最优刀具结构参数为:刺破刀轮廓长度100 mm,宽度95 mm,圆角半径65 mm,刺破刀距离车窗区域A左侧壁和上侧壁的距离分别为45、50 mm。研究了刺破工艺对板料局部应力的影响和零件拉延成形性的影响。结果表明:刺破工艺可以显著降低板料易拉裂位置的局部应力,还可以为零件刺破位置附近的易拉裂区域提供额外的板料流入量,从而降低其减薄率和拉裂风险。依据带刺破工艺的拉延成形方案制造了该车门内板拉延模具并进行了零件试生产,发现试验结果与模拟结果一致,得到了表面质量好、无拉裂缺陷的汽车车门内板零件。

The lancing process was introduced into the drawing process of the inner panel of automobile door. Based on the numerical simulation results, the structural parameters of lancing tool were optimized by response surface method. The optimal structural parameters of the lancing tool were obtained as follows: the outline length of the lancing tool is 100 mm, the width is 95 mm, the round radius is 65 mm, and the distance between the lancing tool and the left wall and the upper wall of the window area A is 45 and 50 mm, respectively. The effects of lancing process on the local stress of sheet metal and the drawing formability of the part were studied. The results show that the lancing process can significantly reduce the local stress of the easy-to-crack position of sheet metal, and can also provide additional sheet metal inflow for the easy-to-crack area near the lancing position of the part, thus reducing the thinning rate and the risk of cracking. According to the drawing forming scheme with lancing process, the drawing die of the inner panel of the door was manufactured and the part was tested. It is found that the test results are consistent with the simulation results, and the inner panel part of the automobile door with good surface quality and no tensile cracking defects is obtained.