汽车一体式门环精度提升

Accuracy Improment of Automotive Integrated Door Ring

汽车一体式热成型门环具有轻量化、强度高、碰撞性能好等优点,但由于零件体积大,定位复杂,模具状态匹配难度大,从而导致一体式门环成型精度差,局部易变形,控制难度大,难以达到生产所需制造精度的要求,目前国内自主品牌车型尚无量产门环。通过某款新车型研发试制,对汽车一体式门环尺寸精度提升进行了系统研究,采用迭代回弹补偿模具型面、调试模具保压间隙、门环定位基准优化和铰链安装面公差偏置等尺寸精度控制措施,并分别在试制阶段和预量产阶段用门环检具检测了6台样品。结果表明,采用精度控制措施后,门环总体制造精度合格率从试制阶段的87.75%提升至预量产阶段的95.90%。

The hot forming integraled door ring has unique advantages on weight reduction, strength improvement and excellent capability of crash. While it is difficult to control the dimensional accuracy and likely to deform in part because of large in size, complicated location and difficult matching of the mould. For the moment integrated door ring hasn′ t been used by any domestic automobile company.Dimensional accuracy of automotive integrated door ring was researched systematically by a new car model development, including iterative springback compensation of the moulding surface, adjustion of the mould holding clearance, optimization of the door ring locating datum and tolerance offset of the hinge fixing surfaces. Six samples were tested with door ring inspection tools in the trial production stage and pre mass production stage. The results show that after the precision control measures are adopted, the overall manufacturing precision qualification rate of the door ring is increased from 87.75% in the trial production stage to 95.90% in the pre mass production stage.