铝合金游艇外板冲压成形缺陷分析及优化设计

Defect Analysis and Optimization Design of Stamping Forming of Aluminum Alloy Yacht Outer Panel

铝合金游艇外板由于造型面积与曲率变化较大,且包含许多局部深抽等复杂特征,使其冲压成形较为困难。为分析其成形缺陷并进行优化设计,采用有限元法对铝合金游艇外板进行冲压特征、缺陷成因及影响因素分析,并提出一种具有平缓特征的工艺补充面设计来克服成形缺陷。数值计算结果表明:降低压料力可改善局部拉伸,但厚度增加较少,通过优化外型参数可改善球鼻艏区域的破裂缺陷,但反向船脊区域的褶皱也因压料力的减小而更加严重;阻料条使反向船脊的褶皱大幅度减少,船首褶皱完全改善;基于平缓特征的工艺补充面造型设计可解决球鼻艏尖点造型所产生的局部拉伸,反向船脊缺陷也得到改善,船尾底壳褶皱缺陷经造型往外延伸得以移至工艺补充面部分。经优化设计后,铝合金游艇外板冲压缺陷均得到改善。

Yacht outer panel is a large-area shape with great curvature change, and includes many complex feature shapes such as local deep drawing, which makes it difficult to punch into yacht outer panel. In order to analyze its forming defects and carry out optimal design, the stamping characteristics, defect causes and influencing factors of the outer panel of the aluminum alloy yacht are analyzed by FEA, and a kind of supplement surface design of rockery process with gentle characteristics is proposed to overcome the forming defects. The numerical results show that the reduction of pressing force can improve the local tension, but the increase of thickness is less. The shape parameters can improve the fracture of the bulbous bow area, but the wrinkling of reverse ridge area is more serious because of the reduction of pressing force. Blocking bar makes the fold of the reverse ridge reduce by large degree, while the bow fold is improved. Based on the gentle feature, the design of the rockery craft supplement surface can solve the local tension caused by the bulbous bow tip modeling. The reverse ridge defect is improved, and the fold defect of the stern bottom shell is also transferred to the craft supplement surface through the outward extension of the modeling. After the optimal design, all the stamping defects of the outer plate of the aluminum alloy yacht are improved.