汽车铝合金地板梁拉延成形工艺模拟分析

Simulation analysis of drawing forming process for automobile aluminum alloy floor beam

借助Dynaform软件,对某汽车的地板梁进行了拉延模设计及有限元模拟成形性能研究。在构建有限元模型的基础上,从制件的冲压方向、工艺补充面、压料面和坯料初始形状等方面进行了设计分析。设计了3种不同的工艺补充方案,研究了各方案的地板梁拉延成形特点。通过分析制件减薄率指标,确定了较优的工艺补充方案:H=55. 4 mm,L1=10 mm,R1=20 mm,R2=30 mm,L2=70 mm。该方案的材料利用率为60. 1%,板料能够顺利流动,切边后得到制件的最大减薄率为18. 2%,制件表面无破裂及起皱。为进一步改善制件的成形质量,增设了拉延筋并对主要参数进行了优化设置。得到最终制件的最大减薄率为19. 1%,且表面成形良好。在模拟分析的基础上对制件进行了实际的冲压试验,实际冲压制件的最大减薄率与模拟结果的误差为3. 14%,符合制件的质量评价标准。

The drawing die was designed and finite numerical simulation formability of the floor beam in an automobile by means of Dynaform software.Based on the construction of the finite element model,the design analysis was carried out from the aspects of the stamping direction,addendum surface,binder surface and the initial shape of blank.Three process supplement schemes were designed,and the drawing characteristics of the floor beam of each scheme was analyzed.By analyzing the thinning rate of the parts,the better process supplement scheme is determined:H=55.4 mm,l1=10 mm,R1=20 mm,R2=30 mm,l2=70 mm.The material utilization of the final part of this process scheme is 60.1%,and sheet can flow smoothly.The final part has no cracks and severe wrinkles with the maximum thinning rate of 18.2%.To further improve the forming quality of the parts,drawbeads were added and the main parameters were optimized.The maximum thinning rate of the final part is 19.1%,and the surface of the part is well formed.The actual stamping test for the part was conducted based on simulation.The error of the maximum thinning rate between the actual part and the finite element modeling results is 3.14%,which meets the quality evaluation standard of the parts.