基于Autoform的车门内板拼焊板成形仿真分析

Simulation analysis of automotive door inner panel stamped for tailor welded sheet forming based on Autoform

分别对开裂的1#板材和不开裂的2#板材的焊缝质量和力学性能进行对比分析,2#试样塑性应变比r值高于1#试样。杯突和金相实验结果表明,两种板材焊缝质量良好,冲压开裂并非由焊缝质量原因造成。通过Autoform软件对1#和2#试样进行仿真分析发现,1#试样在棱角和焊缝薄板侧区域的应变和减薄率均大于2#试样,且最大减薄率达到26.6%,为开裂风险区。同时,利用Autoform-Sigma模块对噪音变量下数模的稳定性进行分析,结果表明其过程能力指数Cpk值低,生产稳定性差。通过仿真优化调整,将焊缝厚板区域的局部拉延筋阻力系数由0.45调整为0.35后,零件开裂风险区域消失,生产稳定性提高。

The weld quality and mechanical properties of the cracked 1#sheet and the non-cracked 2#sheet were compared and analyzed.The plastic strain ratio value r of the 2#sample is higher than that of the 1#sample.The cupping and metallographic experiment results show that the weld quality of the two sheets is good,stamping cracking is not caused by the weld quality.The 1#sample and the 2#sample were simulated using Autoform software,and it is found that the strain and thinning ratio of the 1#sample on the edges and on the thinner sheet side of weld are larger than those of 2#sample.The maximum thinning ratio reaches 26.6%,which results in a high risk of cracking.Meanwhile,The robustness of the digital model with the noise variables was analyzed using Autoform-Sigma module.The results show that the process capability index Cpk is low,and the production robustness is inferior.After the optimization and adjustment with simulation,by adjusting the resistance coefficient of local drawbead in the thicker sheet area of weld from 0.45 to 0.35,the cracking risk area of part disappears,and the production stability is improved.