汽车吸能盒零件多工位级进模设计

Design on multi-station progressive die for automotive energy absorbing box parts

针对厚度大、强度高、成形困难且尺寸精度要求高的汽车吸能盒零件,通过工艺分析确定了直排中间载体的排样设计的14工位级进模冲压方案,材料利用率达75.14%。采用有限元模拟方法分析了产品成形过程中的回弹变形量,通过在侧整形工位施加补偿的方法解决了回弹超差问题;采用先冲孔后成形的方式解决了位于圆角上的溃缩孔无法直接冲裁的问题;采用挂台加背托板的形式固定凸模,解决了冲裁轮廓不封闭引起的冲裁力不平衡的问题;设计了楔形回退机构,解决了零件存在冲压负角无法直接成形的问题。生产试制结果表明,该级进模设计合理可靠,产品质量达到要求,生产效率高。

For the automotive energy absorbing box parts with large thickness,high strength,difficult to form and high dimensional accuracy requirement,the 14-station progressive die stamping scheme for straight-line intermediate carrier layout design was determined through process analysis,and the material utilization rate reached 75.14%.Then,the amount of springback deformation during the product forming process was analyzed by finite element simulation method,and the problem of springback out-of-tolerance was solved by applying compensation at the side shaping station.Furthermore,the method of punching first and then forming was used to solve the problem that the collapsed hole located on the fllet could not be directly blanked,and the punch was fixed in the form of hanging table and a back support plate to solve the problem of unbalanced blanking force caused by unclosed blanking profile.Finally,the wedge-shaped retraction mechanism was designed to solve the problem that the stamping negative angles of parts could not be directly formed.The trial production results show that the progressive die design is reasonable and reliable,the product quality meets the requirements,and the production efficiency is high.