翼子板成形数值模拟与工艺优化

Numerical simulation and process optimization on fender forming

以汽车翼子板为研究对象,根据零件造型复杂、曲率变化大、外观质量要求高等特点,设计了4道工序的成形工艺方案。利用AutoForm软件对翼子板成形工艺方案进行数值模拟,识别了全工序成形过程中,主棱线滑移、前保安装座面圆角开裂、前保配合部立壁起皱、发动机罩搭接部座面回弹大等潜在缺陷。通过调整冲压方向及压料面来改善主棱线滑移,以增大开裂部位圆角半径来解决开裂,以优化工艺补充面来减少起皱,并借助CATIA软件对回弹量过大的部位进行反向补偿设计以降低回弹。结果表明,成形工艺方案优化后,翼子板在成形过程中未发生滑移、开裂和起皱等缺陷,回弹量也控制在可接受范围内,与数值模拟结果基本一致,证明了数值模拟的可靠性。

For the automobile fender, based on the characteristics of complex shape, large curvature variation and high appearance quality requirements etc., a four-step stamping process was designed. Then, the forming process scheme of fender was simulated by software AutoForm, and the potential defects such as major ridgeline slip, cracking at the bottom fillet of bumper fitting area, wrinkle at the wall of bumper fitting area, large springback of hood joint area flange during the whole forming process were identified. Furthermore, the main ridgeline slip was improved by adjusting stamping direction and blank holder surface, the cracking was solved by increasing the fillet radius of cracked area, the wrinkles were reduced by optimizing the process addendum, and the reverse compensation design was conducted on the area with excessive springback to reduce the springback by software CATIA. The results show that after the optimization of the forming process scheme, no defects such as slippage, cracking, wrinkling and so on, occur during the forming process of fender, and the amount of springback is controlled within the acceptable range, which is consistent with the numerical simulation results to prove the reliability of the numerical simulation.