汽车后风挡横梁冲压工艺仿真分析与优化设计

刘斐然 纵荣荣 李乐乐 李梦薇 鹿荣贵 李海鹏

摘要 以某汽车后风挡横梁为研究对象，通过UG软件建立产品的三维数模，结合产品的结构特点及冲压工艺分析，拟定其冲压方案为拉延、修邊冲孔和翻边冲孔。基于Dynaform有限元分析平台，对其拉延成型过程进行有限元数值仿真，获得了润滑条件、拉延速度、拉延筋、模具间隙对拉延成型质量的影响，并采用正交实验方法对各工艺参数进行优化设计，确定了最优的工艺参数组合：拉延速度为1 000 mm/s，压边力为420 kN，坯料与凸模间摩擦系数为0.075（半干摩擦），坯料与凹模间摩擦系数为0.05（边界摩擦），模具间隙为1.2 mm。模拟结果表明，采用优化后的冲压工艺参数可以有效预防零件的起皱、开裂等缺陷。

关 键 词 后风挡横梁;冷冲压;工艺设计;数值模拟;正交实验

中图分类号 TG386.1     文献标志码 A

Stamping process simulation analysis and optimization design for a car-rear-windshield-cross beam

LIU Feiran1， ZONG Rongrong2， LI Lele2， LI Mengwei1， LU Ronggui1， LI Haipeng1，2

（1. School of Materials Science and Engineering， Hebei University of Technology， Tianjin 300130， China; 2. Tianjin Jinliyan Automobile Engineering and Technology Co.， Ltd.， Tianjin 300392， China ）

Abstract The car-rear-windshield-cross beam was adopted as the research object. With its 3D digital model established by UG software and considering the structural features and technical analysis of the product， the stamping process plan was determined as drawing， trimming & piecing and flanging & piecing. The finite element numerical simulation of the drawing process was performed by the Dynaform finite element analysis platform. The influence of blank-holder force， lubrication condition， drawing speed， drawbead and die clearance on the forming quality were obtained. Then orthogonal experimental method was applied to optimize its process parameters and determine the optimal combination of process parameters， that is， draw speed of 1 000 mm/s， blank-holder force of 420 kN， friction coefficient between blank and punch of 0.075 （semi-dry lubrication）， friction coefficient between the blank and the die of 0.05 （boundary lubrication）， and die clearance of 1.2 mm. The simulation results indicate that the optimized stamping process parameters can effectively avoid the defects of the part such as wrinkling and cracking .

Key words rear-windshield-cross beam; cold stamping; process design; numerical simulation; orthogonal experiment

0 引言

目前，在冷冲压模具设计与制造产业中，用于汽车制造领域的冲压模具约占总模具数量的三分之一左右[1]。汽车覆盖件模具是汽车模具的重要组成部分，汽车的制造成本、开发周期和整车性能都与模具设计与制造水平密切相关。然而，区别于常规冲压件，汽车覆盖件具有复杂曲面形状、零件尺寸大、材料厚度薄、成型难度大等特点，导致汽车覆盖件模具设计与制造难度大、成本高、周期长、质量难以控制等问题[2]。随着汽车行业的快速发展，为提高市场竞争力，汽车制造商在提高汽车质量的同时，要求大幅缩减模具研发和制造周期，这对汽车模具设计与制造水平提出了更高要求。……