车窗升降板弯曲成形回弹缺陷的影响因素分析与成形工艺优化

针对弯曲件汽车车窗升降板在成形过程中因板料弹性回复和残余应力的存在易产生回弹而影响零件尺寸和装配性能的问题,借用Dynaform平台对板料弯曲成形过程进行数值模拟及回弹预测。针对板料厚度A、冲压速度B、摩擦因数C和模具间隙D等4项影响因素设计9组不同的成形工艺参数组合,分别对板料进行正交试验和重复正交试验(重复次数S=3)获取回弹结果,并采用极差分析法(方案1)和方差分析法(方案2)进行影响因素的主次排序和工艺优化。方案1和方案2分别获得的影响因素主次顺序和优化工艺参数组合为ABDC,A_2B_2D_3C_2和BDCA,B_2D_3C_2A_1。将两组工艺参数进行对比验证,进而确定最佳参数组合为板料厚度A=0.9 mm,冲压速度B=5000 mm·s~(-1),摩擦因数C=0.125,模具间隙D=1.15。利用该工艺进行试生产,检测零件危险圆角处厚度为t=0.70 mm,减薄率低于25%。经过试装配证明,采用优化后工艺参数成形的零件能够满足其使用条件下的尺寸和装配要求。

Influence factor analysis and forming process optimization on bending springback for window lift plate

For the problem of springback affecting size and assembly performance in the bending process of window lift plate for automobile caused by the existence of elasticity and residual stress of sheet metal, the forming process and the springback prediction were carried out by the Dynaform software.Then, nine sets of different process parameters were designed with four influence factors as the sheet thickness A, the stamping speed B, the friction coefficient C and the mold