基于多工序回弹补偿的大型汽车覆盖件成形优化

Forming optimization of large automobile panel based on multi-process springback compensation

针对某品牌SUV汽车大型覆盖件成形过程存在的易起皱、破裂和回弹等质量问题,进行了工艺参数多目标优化和回弹补偿优化.首先,以最大增厚率和最大减薄率为评价目标,利用正交试验和Design-Expert软件对压边力、模具间隙、冲压速度和摩擦系数进行多目标优化,并确定最优工艺参数组合;其次,以最大回弹量为评价目标,利用多工序补偿法对拉延模和修边冲孔模进行回弹补偿,并对最优冲压工艺参数组合和回弹补偿面进行仿真分析和试模实验.研究表明:优化后的成形工艺参数能够防止零件破裂,减少起皱以及降低最大增厚率和最大减薄率;多工序回弹补偿能够有效控制回弹量,减少整形工序.本文的优化方案可为提高大型汽车覆盖件的成形质量和节约成本提供参考.

Aiming at the quality problems of wrinkling,cracking and springback in the forming process of a brand SUV large panel,multi-objective optimization of process parameters and springback compensation optimization were carried out.Firstly,taking the maximum thickening rate and the maximum thinning rate as the evaluation objectives,the multi-objective optimization of blank holder force,die clearance,stamping speed and friction coefficient was carried out by using orthogonal test and design expert software,and the optimal combination of process parameters was determined;Secondly,taking the maximum springback as the evaluation objective,the multi-process compensation method is used to compensate the springback of the drawing die and trimming punching die,and the optimal stamping process parameter combination and the springback compensation surface are simulated and tested.The results show that the optimized forming process parameters can prevent parts from cracking,reduce wrinkling,and reduce the maximum thickening rate and the maximum thinning rate;multi-process springback compensation can effectively control the springback and reduce the shaping process.The optimization scheme in this paper can provide a reference for improving the forming quality of large automobile panels and saving costs.