基于正交实验的弯链板U弯冲压成形数值仿真

Numerical simulation on U-bending for curved chain plate based on orthogonal experiment

为分析凹模圆角半径、凹凸模单边间隙和凸模补偿回弹角对弯链板U弯冲压成形的影响,设计了3因素4水平的正交实验,利用Workbench对16组实验进行U弯冲压成形数值仿真,并计算仿真成形工件的尺寸偏差比。以冲压仿真成形模型尺寸与工艺尺寸的误差最小为目标,利用综合加权评分法进行整体极差分析与方差分析,得到模具的最优工艺参数。结果表明:当凹模圆角半径为8 mm、凹凸模单边间隙为4.35 mm、凸模补偿回弹角为0.05°时,弯链板的U弯冲压成形效果最好,为模具的最优工艺设计参数。通过模具样机实验验证,U弯冲压成形后工件的合格率在97.7%以上,基本达到了预期的工艺设计要求。

In order to analyze the influence of die fillet radius,unilateral clearance between die and punch and compensation springback angle of punch on U-bending of curved chain plate,an orthogonal experiment with three factors and four levels was designed,and sixteen groups of experiments were simulated numerically by Workbench to calculate the dimensional deviation ratio of the simulated forming workpiece.Then,with the goal of minimizing the error between the dimensions of the stamping simulation forming model and the process dimensions,the overall range analysis and the variance analysis were performed by the comprehensive weighted scoring method to obtain the optimal process parameters of mold.The results show that when the die fillet radius is 8 mm,the unilateral clearance between die and punch is 4.35 mm,and the compensation springback angle of punch is 0.05°,the U-bending effect of the curved chain plate is the best,which is the optimal process design parameters of mold.Through the experimental verification of mold prototype,the pass rate of workpiece after U-bending is over 97.7%,which basically meets the expected process design requirements.