基于CAE汽车覆盖件拉伸成形工艺优化与模具设计

Optimization of Drawing Forming Process and Die Design of Automobile Panel Based on CAE Software

针对汽车上某一覆盖件,根据形状特点,对制件冲压方向、工艺补充面、压料面及坯料形状大小等进行分析设计,并利用CAE分析软件FASTAMP对拉伸成形过程进行了模拟仿真,从材料厚度分布、减薄率、成形极限图等方面预测了拉伸过程中成形不足、过度减薄和起皱等缺陷,分析原因并优化设计,最终确定了合理的拉伸成形工艺方案。结果表明:设置拉伸筋可得到成形质量较好的冲压件,并有效消除制件表面的起鈹缺陷;采用变半径圆角的方法,使制件最大减薄率由原来的20.5%降至16.5%,满足制件生产要求。

For an automobile panel,the product of stamping direction,addendum surface,blank holder face and billet sizeare studied in this paper.The forming process is simulated by CAE software FASTAMP.The insufficient forming,excessive thinning and wrinkling defects in the drawing process are predicted from the aspects of material thickness,thinning ratio and forming limit diagram.Then,the proper forming process is determined by analyzing the causes of defects and optimization design in many times.The results show that the stamping parts with good forming quality can be obtained by setting up drawbead,and the wrinkling defects on the surface of the product can be effectively eliminated.The maximum thinning rate of the product is reduced from 20.5% to 16.5% by using the method of variable fllet,which meets the qualified requirement of the automobile panel.