减震器顶板变形控制与成形模设计

Deformation control and forming die design for shock absorber top plate

减震器顶板是一个结构复杂的非对称工件,此类工件的成形一直是冲压工艺的难点。根据企业生产的减震器顶板中出现的质量问题,运用Dynaform仿真软件,对减震器顶板工件的成形机理进行了研究,分析了减震器顶板质量问题产生的原因,并提出了解决的工艺方案;采用一模二件成形方法,将非对称结构成形转化为对称结构成形,在工件成形时,利用相互约束的材料变形阻力来控制材料变形,利用成形模结构来控制工件变形顺序,提高了工件成形质量及模具寿命;对减震器顶板成形模具设计及制造提出了合理建议。通过企业生产证明,优化后的生产工艺及成形模具不仅减小了减震器顶板成形后的回弹量,还提高了减震器顶板尺寸精度、几何形状精度和生产效率,降低了生产成本。

The top plate of shock absorber is an asymmetric workpiece with complex structure,and the forming of this kind of workpiece has been a difficulty point in the stamping process.Therefore,according to the quality problems in the top plate of shock absorber pro-duced by the enterprise,the forming mechanism of the top plate workpiece for shock absorber was studied by simulation software Dy-naform,the causes of the quality problems for the top plate of shock absorber were analyzed,and the solution process scheme was put for-ward.Then,the asymmetrical structure forming was transformed into symmetrical structure forming by the forming method of two pieces in one mold.During the workpiece forming,the deformation of material was controlled by the mutual constraint resistance of material deform-ation,and the deformation sequence of workpiece was controlled by the forming mold structure,which improved the forming quality of workpiece and the life of mold.Furthermore,the reasonable suggestions were put forward for the design and manufacture of the forming mold for the top plate of shock absorber.The enterprise production shows that the optimized production process and forming mold not only reduce the springback amount for the top plate of shock absorber after forming,but also improve the dimensional accuracy,the geometric shape accuracy and the production efficiency for the top plate of shock absorber,and reduce the production cost.