车身内板件拉延成形仿真与工艺参数优化

Drawing Simulation and Process Parameter Optimization of Body Inner Panel

针对某型车身内板件,采用极差分析优化正交仿真试验的方法,建立制件的拉延工序三维有限元模型,研究拉延成形工艺参数中拉延筋线扩大尺寸L、可变拉延筋约束力F_(R1)与F_(R2)和压边圈压边力Q对最大减薄率T_(max)的影响。试验结果表明:影响T_(max)因素的主次关系为F_(R1)>F_(R2)>Q>L;应用分析出的最优工艺参数组仿真,T_(max)为-0.2198,次于最优水平和次优水平,说明对T_(max)具有明显的优化增益作用;应用分析出的最次工艺参数组仿真,T_(max)为-0.2362,仅次于最次水平,说明对T_(max)具有明显的优化减益作用。仿真结果表明:优化增益时,成形不充分区域面积被增大;优化减益时,成形不充分区域面积被消除,原因是进料量的变化引起的板料对凸模贴合张力变化所致。

In this paper,a 3D finite element model of the drawing process of a car body inner panel is established by using the method of range analysis and optimization orthogonal simulation test.The influence of the drawbead line expansion size L,variable drawbead binding force F_(R1),variable drawbead binding force F_(R2) and blank holder force Q on the maximum thinning rate T_(max) are studied.The experimental results show that the primary and secondary relationship of the factors affecting T_(max) is F_(R1)>F_(R2)>Q>L,T_(max) is-0.2198,second only to the optimal level and suboptimal level,which indicates that T_(max) has obvious optimization gain effect;T_(max) is-0.2362,second only to the worst level,which indicates that T_(max) has obvious optimization benefit reduction effect.The simulation results show that the area of under formed area is increased when the gain is optimized,and the area of under formed area is eliminated when the gain is optimized,which is due to the change of sheet metal to punch bonding tension caused by the change of feed rate.