A柱加强板热成形拐角开裂起皱优化

Optimization on wrinkle and crack at corner of A-pillar reinforcement panel in thermoforming

对汽车超高强度硼钢A柱加强板拐角开裂、起皱问题的优化方法进行了研究。利用CAE仿真软件AutoForm创建分析模型,进行热成形冲压仿真模拟分析,分析结果表明,该A柱加强板的拐角处易出现开裂和起皱现象。重点对起皱、开裂问题的原因进行了分析,认为产品结构不合理和工艺补充不优是造成拐角起皱、开裂的主要原因。从产品结构、工艺补充、坯料尺寸方面,经过多轮优化分析,有效地解决了A柱加强板拐角处的成形性问题。依据最优方案进行热成形工艺模具结构设计,经过铸造、机加、研配制造出满足设计要求的模具结构,并进行上机现场调试,调试结果与前期CAE分析结果一致。研究结果表明,前期CAE优化分析结果可以有效地指导现场生产调试,解决了拐角处的成形性问题,最终调试出合格产品,减少了零件开发的成本和周期。

The optimization method of wrinkle and crack at the corner of A-pillar reinforcement panel for automobile ultra-high strength boron steel was studied. The analysis model was created by CAE simulation software AutoForm,and the simulation analysis of thermoforming process was conducted. The analysis results show that it is easy to produce crack and wrinkle at the corner of A-pillar reinforcement panel.Therefore,the reasons caused the wrinkle and crack were analyzed emphatically,and it was believed that the unreasonable product structure and poor process addendum were the main reasons for the wrinkle and crack at the corner. Furthermore,from the aspects of product structure,process addendum and blank sizes,the formability at the corner of A-pillar reinforcement panel were effectively solved by the multiple optimization analysis. According to the optimal plan,the die structure in the thermoforming process was designed and manufactured by casting,machining and polishing to satisfy the design requirement,and the on-site commissioning was conducted. The commissioning results were consistent with the previous CAE analysis results. The research results show that the previous CAE optimization analysis results can effectively guide the production and commissioning on site,the formability at the corner are solved,and the qualified product is produced finally to reduce development costs and cycles of part.