汽车发罩外板冲压回弹补偿研究

Springback compensation research of stamping for automobile hood outer plate

以某车型发罩外板为研究对象,通过对该零件的工艺进行模拟分析,计算每一道工序应力释放后的回弹矢量,同时,考虑每一道工序的上模压料板与下模贴合时对工序件的附加变形所引起的材料流动以及回弹,选择合理的补偿方案,精准地模拟并评价回弹矢量,基于补偿数据进行A面重构,并根据重构优化后的数据进行方案验证以及现场出件验证。现场出件结果表明:产品A面区域的调试工作量降低了60%,首件尺寸合格,与模拟预测结果一致,模具无机加整改工作,有效地解决了发罩外板零件回弹不稳定的难题。结果表明,所提到的方法对提高CAE模拟的准确性、提升回弹补偿精度、避免模具装配后的型面机加整改、降低模具调试优化轮次、提前达到装车要求具有重要的指导意义。

For the hood outer plate of a certain car,the springback vector after the stress release of each process was calculated by the process simulation analysis of the part.At the same time,considering the material flow and springback caused by the additional deformation of process parts when the pressed plate in the upper die was contacting with the lower die in each process,the reasonable compensation scheme was selected.Then,the spingback vector was simulated and evaluated exactly,and A-surface restructure was conducted by the compensation data.Based on the reconstructed and optimized data,the scheme was verified by producing the parts on site.The results show that the try-out work of the A-surface area for product is reduced by 60%,and the first part is qualified in size,which is consistent with the simulation prediction result.So the die does not require rectification work to solve the problem of the unstable springback for hood outer plate effectively,and the method proposed has important guiding significance for improving the accuracy of CAE simulation and springback compensation,avoiding the rectification of surface machining after die assembly,reducing the optimization times of die debugging,and meeting the requirements for assembling the whole car in advance.