后法兰盘翻孔翻边复合成形工艺研究

Research on process parameters of flanging and holing composite forming of rear flange

研究了汽车消声器后法兰盘内孔翻孔和外缘翻边采用复合模成形时的质量问题,首先利用Dynaform有限元软件分析各单一工艺参数对成形质量的影响,确定主要的影响因素,然后针对各主要因素进行正交试验设计,采用极差法分析各因素的影响顺序和显著性,以最小壁厚取值最大、内孔翻孔高度和外缘翻边高度分别满足(15.2±0.5)mm和14.2-1.0+0.5mm要求选取最优工艺参数组合。最终将选取最优工艺参数组合进行试模,获得的法兰盘最小壁厚为2.187 mm,内孔翻边高度为14.9 mm,外缘成形高度为13.8 mm,零件成形质量良好,没有出现开裂与起皱。应用基于正交试验设计方法预测和控制成形质量,减少了试模次数,降低了生产成本,为此类零件的研究提供了参考。

The quality problems of the inner hole plunging and outer edge flanging of the rear flange plate of automobile silencer were studied. Firstly, the Dynaform finite element software was used to analyze the influence of each single process parameter on the forming quality, so as to determine the main influencing factors. Then the orthogonal test was designed for each main factor,and the range method was used to analyze the influence sequence and significance of each factor.The minimum wall thickness and maximum, inner hole plunging height and outer edge flanging height met(15.2±0.5) mm and 14.2-1.0+0.5mm requires respectively to select the optimal process parameter combination. Finally, the optimal process parameters were selected to test the die. The minimum wall thickness of the flange plate was 2.187 mm, the inner hole flanging height was 14.9 mm,and the outer edge forming height was 13.8mm. The forming quality of the part was good without cracking and wrinkling. The method based on orthogonal experimental design was used to control and predict the forming quality, which reduced the number of die test and the production cost.