基于正交试验的汽车翼子板拉伸成形仿真研究

Research on Drawing Simulation for Automobile Fender Based on Orthogonal Experiment

汽车覆盖件拉伸成形后的最大减薄率和最大增厚率可以反映材料的开裂和起皱趋势,针对汽车翼子板拉伸成形易产生开裂、起皱等问题,通过有限元分析与正交试验相结合的方法,以零件的最大减薄率和最大增厚率为评价指标,分析了压边力BHF、摩擦系数μ、材料厚向异性系数r、材料屈服强度σs、材料抗拉强度Rm对零件减薄率和增厚率的影响。利用极差和方差分析,确定了各因素对减薄率和增厚率影响的主次顺序,得出不同因素对减薄率和增厚率的显著性,从而获得了最优的工艺及材料参数组合为:BHF=900kN,μ=0.14,r=1.9,σs=150MPa,Rm=300MPa。将最优工艺、材料参数组合用于实际试模验证,得到了无开裂、起皱,成形充分的零件。研究表明:基于正交试验的有限元分析能够有效提供翼子板的成形质量。

The maximum thinning rate and maximum thickening rate of the automobile panel after drawing could reflect the cracking and wrinkling trend of the material. Aiming at the problem of easy cracking and wrinkling in the drawing of automobile fender, the finite element analysis and orthogonal experiment method were combined to research the drawing process.Based on the maximum thinning rate and maximum thickening rate of the part, the blank holder force BHF, the friction coefficient μ, the material thickness anisotropy index r, the material yield strength σs, and the material tensile strength Rm influences on the thinning rate and thickening rate of part were analyzed. Using range and variance analysis, the primary and secondary order of the influences of various factors on the thinning rate and thickening rate were determined, and the significance of different factors on the thinning rate and thickening rate was obtained, so as to obtain the optimal process and material parameters combination was BHF=900 kN, μ=0.14, r=1.9, σs=150 MPa, Rm=300 MPa. The optimal process and material parameters combination was used for actual die trial verification, and a fully formed part without cracks, wrinkles was obtained. Research shows that the finite element analysis based on orthogonal experiment can effectively provide the forming quality of the fender.