汽车后风挡横梁冲压工艺仿真分析与优化设计

Stamping process simulation analysis and optimization design for a car-rear-windshield-cross beam

以某汽车后风挡横梁为研究对象,通过UG软件建立产品的三维数模,结合产品的结构特点及冲压工艺分析,拟定其冲压方案为拉延、修边冲孔和翻边冲孔。基于Dynaform有限元分析平台,对其拉延成型过程进行有限元数值仿真,获得了润滑条件、拉延速度、拉延筋、模具间隙对拉延成型质量的影响,并采用正交实验方法对各工艺参数进行优化设计,确定了最优的工艺参数组合:拉延速度为1 000 mm/s,压边力为420 kN,坯料与凸模间摩擦系数为0.075 (半干摩擦),坯料与凹模间摩擦系数为0.05 (边界摩擦),模具间隙为1.2 mm。模拟结果表明,采用优化后的冲压工艺参数可以有效预防零件的起皱、开裂等缺陷。

The car-rear-windshield-cross beam was adopted as the research object.With its 3D digital model established by UG software and considering the structural features and technical analysis of the product,the stamping process plan was determined as drawing,trimming&piecing and flanging&piecing.The finite element numerical simulation of the drawing process was performed by the Dynaform finite element analysis platform.The influence of blank-holder force,lubrication condition,drawing speed,drawbead and die clearance on the forming quality were obtained.Then orthogonal experimental method was applied to optimize its process parameters and determine the optimal combination of process parameters,that is,draw speed of 1000 mm/s,blank-holder force of 420 kN,friction coefficient between blank and punch of 0.075(semi-dry lubrication),friction coefficient between the blank and the die of 0.05(boundary lubrication),and die clearance of 1.2 mm.The simulation results indicate that the optimized stamping process parameters can effectively avoid the defects of the part such as wrinkling and cracking.