基于Dynaform的铝合金汽车地板梁成形分析及工艺参数优化

Forming analysis and process parameters optimization for automobile aluminum alloy floor beam based on Dynaform

为实现汽车的轻量化,对某轿车的铝合金地板梁的拉延成形进行研究,运用Dynaform软件对其成形过程进行模拟分析,研究了压边力F、摩擦系数f、冲压速度v及凸凹模间隙c对地板梁成形的影响规律。对上述4个工艺参数进行了正交优化,获得了最优的工艺参数组合:压边力1200 k N,摩擦系数0. 12,冲压速度2000 mm·s-1,模具间隙2. 835 mm。最终制件的成形效果良好,最大减薄率为21. 01%,最大增厚率为6. 25%。在模拟分析及正交优化的基础上对制件进行了实际的拉延试验,实际拉延制件的最大减薄率与最大增厚率与模拟结果的误差分别为2. 4%、6. 2%,均符合制件的质量评价标准。

To realize the lightweight of automobile,the drawing forming of aluminum alloy floor beam of a car was studied,and the forming process was simulated by Dynaform software.The influence of blank holder force F,friction coefficient f,drawing speed v and mold clearance c on the floor beam forming was studied.The orthogonal optimization was carried out for the aforementioned four process parameters,and the optimum combination of process parameters was obtained:blank holder force 1200 k N,friction coefficient 0.12,drawing speed of 2000 mm·s-1 and mold clearance of 2.835 mm.The final part has good forming effect,and the maximum thinning rate and the maximum thickening rate of the final part are 21.01%and 6.25%,respectively.On the basis of the simulation analysis and orthogonal optimization,the drawing experiment was carried out,and the error of the maximum thinning rate and the maximum thickening rate between the simulation results and the experimental ones are 2.4%and 6.2%,respectively,which conform to the quality evaluation standard of workpiece.