基于S型皮卡纵梁起皱扭曲回弹的工艺优化及模具设计

Process optimization and die design based on wrinkling,twisting and springback of S-shape pickup longitudinal beam

重点围绕S型皮卡纵梁的起皱、扭曲、回弹难点,进行前期制件分析,并结合冲压CAE仿真分析,从材料优化、采用压料翻边一次成形、压料翻边空开设计、过弯成形、采用合理的成形凸凹模间隙以及设计弹性感应检测器和浮料顶升6个方面进行解决。研究结果表明:采用压料翻边一次成形工艺可以很好地控制成形过程中的材料流动,产品不再起皱和扭曲。同时采取过弯成形,可减少成形过程中的回弹量。在模具设计方面,对压边进行空开设计可避免顶坏产品;设计合理的凸凹模间隙不仅可以提高镶块的使用寿命,也可对产品回弹做进一步控制。该工艺实践结果良好,满足预期要求,不仅提高了产品质量,也降低了生产成本。

Focusing on the difficulties of wrinkling,twisting and springback for S-shape pickup longitudinal beam,preliminary part analysis was conducted,and combining with CAE simulation analysis of stamping,the problems were solved from six aspects,namely,material optimization,one-time forming of pressing and flanging,open design in pressing and flanging,over bending,using reasonable forming clearance between punch and die,and designing elastic sensing detection and float lifting.The results show that the one-time forming process of pressing and flanging effectively controls the material flow during the forming process,and the product does no longer wrinkles or twists.Simultaneously,over bending reduces the springback amount during the forming process.In terms of die design,open design in pressing avoids damaging the product,and designing a reasonable clearance between punch and die not only improves the service life of insert,but also further controls the springback of product.The practical results of this process are good and meet the expected requirements,which not only improves the product quality but also reduces the production costs.