基于正交试验的椭球状管件内高压胀形参数优化

Optimization of process parameters for high-pressure bulging in an ellipsoidal tube based on orthogonal test

椭球状吸能盒作为汽车防撞系统中重要的吸能结构,在碰撞瞬间通过塑性变形吸收大部分能量,该类管件具有分散外在均布载荷的优良力学性能,故提高此类管件的生产效率显得尤为重要。为此提出了使用内高压胀形工艺制造椭球状吸能盒的方法,此工艺实现了吸能盒轻量化,同时消除了焊缝对吸能盒力学性能的影响,从而使吸能效果较传统吸能盒大幅提升。针对椭球状管件内高压胀形参数的优化,采用有限元仿真结合正交试验的方法,分别研究了波状诱导结构直径、胀形压力以及两侧冲头轴向进给对胀形效果的影响,所得的优化参数:波状诱导结构直径为8 mm,胀形压力为25 MPa,两侧冲头轴向进给为8 mm。采用最优参数进行胀形试验,验证了基于有限元仿真结合正交试验方法获取工艺参数的正确性,并为椭球状吸能盒的制造提供了参考。

As an important energy-absorbing structure in automobile anti-collision system,the ellipsoidal energy-absorbing box absorbs most of the energy through plastic deformation at the moment of collision.This kind of tube has excellent mechanical properties of dispersing external uniform load,so the improvement of production efficiency of this kind of tube is particularly important.Therefore,the method of manufacturing ellipsoidal energy absorbing box by internal high pressure bulging process was proposed.This process realizes the lightweight of energy absorbing box,and eliminates the influence of weld on the mechanical properties of energy absorbing box,so that the energy absorbing effect is greatly improved compared with the traditional energy absorbing box.Aiming at the high pressure bulging in ellipsoidal tube,the effects of the diameter of induced structure,bulging pressure and axial feed on the bulging results were studied by finite element simulation and orthogonal test.The optimized parameters are as follows:the diameter of induced structure is 8 mm,the bulging pressure is 25 MPa,and the punch feed is 8 mm.The optimal parameter bulging test verifies the correctness of the process parameters obtained based on finite element simulation and orthogonal test method,and provides a reference for the manufacture of ellipsoidal energy absorbing box.