前防撞梁拉延成形过程分析及工艺参数优化

Analysis of drawing process and optimization of process parameters for front anti-collision beam

采用Dynaform软件对某汽车前防撞梁成形过程进行了模拟,分析了不同形式的工艺补充面对零件成形的影响,以减薄率为评价标准,最终选取凸模圆角半径25 mm、凹模圆角半径15 mm的两端补充形式和符合零件形状的非平面压料面。采用正交试验法研究了压边力、冲压速度、摩擦因数和模具间隙4个工艺参数对成形结果的影响,获得了工艺参数优化组合为:压边力1100 kN、摩擦因数0.17、冲压速度3000 mm·s^(-1)、凸凹模间隙1.2 t,优化后制件最大减薄率为21.8%,符合制件要求标准。采用优化后的参数进行了实际拉延试验,结果显示,最大减薄率为21.6%,制件成形规律与模拟结果一致。

The forming process of an automobile front anti-collision beam was simulated using Dynaform software,and the influence of different forms of process supplements on the forming of part was analyzed.Taking the thinning rate as the evaluation standard,the two ends supplementary form with the punch fillet radius of 25 mm and the die fillet radius of 15 mm and the non-planar binder surface conforming to the part shape were finally selected.The influence of blank holder force,stamping speed,friction factor and die clearance on forming results was studied using orthogonal test method.The optimal combination of process parameters was obtained as follows:blank holder force of 1100 kN,friction factor of 0.17,stamping speed of 3000 mm·s^(-1),clearance between punch and die of 1.2 t.The maximum thinning rate of parts after optimization is 21.8%,which accords with the required standards of parts.The actual drawing test with optimized parameters was carried out.The results show that the maximum thinning rate is 21.6%,and the forming law of the parts is consistent with the simulation result.