面向产品设计的铝合金件翻边成形

以某车身铝合金内板件为研究对象,利用有限元模拟软件ABAQUS建立了翻边及回弹过程的有限元模型。通过优化上弯曲半径R1、下弯曲半径R2、翻边角度α等3个产品特征参数和润滑条件μ、模具间隙T等两个工艺参数,来减小回弹值和降低弯裂风险。结合正交试验和灰色关联的方法将多目标问题转化为单目标问题,得到较优的设计参数指导产品设计,并进行试验验证。结果表明,影响综合目标的主次顺序为:模具间隙翻边角度上弯曲半径下弯曲半径摩擦系数,得到优化后的组合参数为R1=5 mm,R2=9 mm,a=75°,μ=0.1,T=t,采用优化后的参数设计零件,得到的实际零件的回弹在公差范围内且无弯裂缺陷。

Flanging of aluminum alloy part for product design

For the aluminum alloy inner panel in a car body,a finite element model for the flanging and springback process was established by FE software ABAQUS,and the values of springback and crack risk were reduced by optimizing three character parameters of upper bending radius R1,lower bending radius R2 and flanging angle α and two process parameters of friction coefficient μ and die clearance T.Then,the multi-objective parameter optimization problem was transformed into a single target problem by combining orthogonal test with grey correlation analysis to get a better parameter in order to guide product design,and it was experimentally validated.The result shows that the sequences influencing on integrated target are die clearance,flange angle,upper bending radius,lower bending radius and friction coefficient.The optimized combination parameters are obtained with R1=5 mm,R2=9 mm,a=75°,μ=0.1 and T=t.The actual product is within the tolerance range of springback and without the defect of bend crack,when the optimized parameters are used to design the product.