基于冲压同步工程的铝合金侧围外板造型优化

Modeling optimization on aluminum alloy side outer panel based on stamping synchronous engineering

为了解决铝合金汽车覆盖件在冲压生产过程中常见的开裂、起皱与回弹等问题,以某铝合金汽车侧围外板为例,对零件进行了工艺性分析;借助Autoform软件快速设计了工艺补充造型与料片形状,并最终以此为基础进行了冲压全工序仿真。模拟结果表明:同步工程阶段优化原始零件造型可以使其在设计上规避冲压缺陷:将开裂区域的圆角进行球化处理并将连续台阶造型进行平缓过渡设计可以缓解开裂风险;在起皱区域设置额外的吸皱造型与翻边豁口可以缓解起皱;设计加强筋和增加结构约束可以减小回弹量;避免造型特征干涉可以降低冲压曲面的变形缺陷。最终成功制造了优化后的零件,且质量良好,证明该方法可有效减少后期冲压模具开发的时间与成本、提高产品质量,为相似制件提供了良好的结构改进参考。

In order to solve the problems such as cracking,wrinkling and springback of aluminum alloy automobile cover panel during stamping production process,for an aluminum alloy automobile side outer panel,the processability of part was analyzed.Then,the process supplementary modeling and sheet shape were quickly designed by software Autoform,and the whole stamping process simulation was carried out on this basis.The simulation results show that the optimization of the original part modeling in synchronous engineering stage can avoid the stamping defects in the design,spheroidizing the fillet in the cracked area and designing a smooth transition in the con-tinuous step modeling can alleviate the cracking risk,setting additional wrinkle absorption modeling and flanging gap in the wrinkle area can alleviate wrinkling,designing stiffeners and adding structural constraints can reduce the springback amount,and avoiding the interfer-ence of modeling features can reduce the deformation defects of the stamping surface.Finally,the optimized part is successfully manufac-tured with good quality,which proves that this method can effectively reduce the time and cost of later stamping die development,improve the quality of product,and provide a good reference for structural improvement of similar parts.