一种基于预压弯的新型扭力梁回弹补偿方法

A springback compensation method on new torsion beam based on pre-compression bending

针对一种新型轴线带弯曲特点的扭力梁成形,给出了其两步充液成形的工艺参数,并利用有限元模拟软件给出了对成形质量的预测。结果表明,在最大支撑压力为55 MPa、最大整形压力为295 MPa、推头补给量为15 mm的工艺参数组合下,其成形无破裂和起皱风险。此外,对该零件轴线易发生的Z向回弹进行了模拟研究。结果显示,该零件成形后存在5 mm以上的偏差量。基于此,提出了一种预成形前预压补偿的回弹补偿方法,通过数值模拟实验和零件试制对该方法进行了验证。结果表明,该种方法可以将Z向回弹控制在0.6 mm以内,能够满足精度要求,为之后管类零件成形的回弹控制提供了参照。

For the forming of a new type of torsion beam with bending characteristics on axis, the process parameters of its two-step hydroforming were given, and the prediction of forming quality was given by finite element simulation software. The results show that under the combination of process parameters for the maximum supporting pressure of 55 MPa, the maximum shaping pressure of 295 MPa and the feeding amount of 15 mm at both ends for tube, there is no risk of cracking and wrinkling in forming process. In addition, the Z-direction springback that is prone to occur in the axis of part was studied by simulation. The results show that there is a deviation of more than 5 mm after the part is formed. Based on this, a springback compensation method for pre-compression compensation before pre-forming was proposed, which was verified by numerical simulation experiments and part trial production. The results show that this method can control the springback in the Z-direction within 0.6 mm to meet the accuracy requirements and provide a reference for the springback control of subsequent tube part forming.