基于正交试验的侧围外板拉延成形工艺参数优化研究

Research on Optimization of Drawing Process Parameters for Side Outer Panel Based on Orthogonal Test

针对侧围外板拉延成形易产生开裂、起皱以及塑性变形不充分等问题,以某车型侧围外板为研究对象,对影响侧围外板拉延成形质量的工艺参数进行研究。运用单因素变量法,研究了压边力、冲压速度、摩擦系数、模具型面间隙以及拉延筋阻力系数五个变量因素对侧围外板拉延成形质量的影响。运用正交试验法和极差分析法,以降低最大减薄率为目标进行优化,筛选出最佳工艺参数组合。明确了各变量因素对侧围外板最大减薄率主次影响的优化方法,并分析了试验结果方差,得出了影响减薄率的显著因素。运用优化后的工艺参数进行成形仿真,获得了良好的成形效果。利用成形仿真结果指导现场试模,得到无开裂、起皱、塑性变形充分的零件,最大减薄率为19.8%,最大增厚率为3.6%。研究表明,将正交试验应用于成形仿真可以改善侧围外板拉延成形质量,并能提高试模成功率。

Cracking,wrinkling and insufficient plastic deformation easily occur in the drawing of the side outer panel.To address these problems,this paper takes the side outer panel of a certain vehicle model as the research object,and studies the process parameters affecting the drawing quality of the side outer panel.Using the single factor variable method,the paper studies the influence of 5 variable factors of blank holder force,stamping velocity,friction coefficient,die surface clearance and drawbead resistance coefficient on the drawing quality of the side outer panel.The orthogonal test method and the range analysis method are used to optimize the target to reduce the maximum thinning rate,and to screen out the best combination of process parameters.The optimization method of the influence of various variables on the maximum thinning rate of the side outer panel is clarified,the variance of the test results is also analyzed,and the significant factors affecting the thinning rate are both obtained.The optimized process parameters are used for drawing simulation,and a good drawing effect is obtained.The results of drawing simulation is used to guide the die tryout,a part with no cracks,wrinkles,and sufficient plastic deformation is obtained.The maximum thinning rate is 19.8%and the maximum thickening rate is 3.6%.Research shows that applying orthogonal experiment to forming simulation can improve the drawing quality of the side wall outer panel and increase the success rate of die tryout.