电动汽车电池包铝合金顶盖拉延成形分析及工艺参数优化

Drawing Forming Analysis and Process Parameter Optimization of Aluminum Alloy Top Cover of Battery Pack for Electric Vehicle

目的解决轻薄铝合金电池包顶盖拉延成形过程中的工艺质量问题。方法采用Autoform软件对顶盖拉延成形过程进行仿真分析,在单一条件下分别研究压边力、冲压速度、凹凸模间隙以及摩擦因数对顶盖拉延成形规律的影响。以最大减薄率和最大增厚率为评价指标,通过对以上4个工艺参数进行正交实验优化,且采用正交综合评分法分析实验数据,得出影响评价指标的4个因素的主次关系(冲压速度>压边力>摩擦因数>凹凸模间隙)以及最优工艺参数。结果最优工艺参数如下:冲压速度为1000 mm/s,压边力为800 kN,摩擦因数为0.12,凹凸模间隙为1.26 mm。采用最优工艺参数进行拉延成形实验验证,实验后测量实物顶盖,实际最大减薄率为14.3%,最大增厚率为8.6%。与仿真值比较,顶盖的实际最大减薄率误差为8.9%、最大增厚率误差为7.5%,实际值与仿真值之间的误差合理。结论在实际生产中,该工艺参数优化的方法能够为后续轻薄铝合金顶盖的生产制造提供有价值的指导。

The works aims to solve the process quality problems existing in deep drawing forming of top cover of thin aluminum alloy battery pack.The AutoForm approach was used to simulate and analyze the process of top cover drawing forming,and the effects of blank holder force,stamping speed,concave and convex die clearance and friction coefficient on the top cover drawing forming law were studied under a single condition.Through orthogonal experiment optimization of the above four process parameters,and with the maximum thinning rate and the maximum thickening rate as the evaluation index,the orthogonal comprehensive scoring method was used to analyze the experimental data.After analysis,the primary and secondary relationship(stamping speed>blank holder force>friction coefficient>concave and convex die clearance)of the four factors was obtained and the optimal process parameters(stamping speed of 1000 mm/s;blank holder force of 800 kN;friction coefficient of 0.12;concave and convex die clearance of 1.26 mm)were determined which were then adopted for experimental verification of deep drawing.After the experiment,the maximum thinning rate was 14.3%and the maximum thickening rate was 8.6%.The results indicated that the error of the maximum thinning rate was 8.9%and the error of the maximum thickening rate was 7.5%.The error between the actual value and the simulation value was reasonable.In actual production,the optimization method of process parameters can provide valuable guidance for the subsequent production and manufacture of thin and light aluminum alloy to cover.