汽车外覆盖件表面凹陷与畸变的实验与仿真

剧烈的市场竞争驱使汽车制造商从各方面设法提高其产品的质量。汽车外覆盖件的"A"级表面要求必须是光洁无瑕。可是由于制造过程的原因,在汽车外覆盖件的"A"级表面上还经常出现一些缺陷。在研究中,设计并制造了4种不同的实验模具,实验模具中包含了在汽车外覆盖件容易产生表面畸变的典型的反拉延特征。通过冲压实验,观察到表面缺陷的产生,并搜集产生表面缺陷处的应变及位移的历史数据,及在畸变区域的接触压力的数据。同时,还进行了冲压过程的数值模拟,模拟计算的结果与冲压实验的结果基本一致。通过冲压实验成功复制了在汽车外覆盖件上经常出现的表面缺陷,为进一步研究在汽车外覆盖件的"A"级表面上产生表面凹陷与畸变的根源奠定了基础。

Research on experiment and simulation of automobile panel surface low and distortion

Fierce market competition has driven automotive manufacturers to improve the quality of their cars and trucks in every aspect.The Class "A" surface of automobile's outer panel determines the appearance of the vehicle and needs to be clean.However,many defects are frequently introduced into the Class "A" surface during the manufacturing process.In research,designed and manufactured four different experimental dies containing typical automobile outer panel product features that commonly cause surface low and distortion.Then we ran stamping tests using the experimental dies,observed the development of the surface distortion,and collected the historical data of stains,contact pressure around the distortion area.The finish panels of stamping test produced the surface low and distortion as expected.At the same time the stamping process was numerically simulated.And the results of analysis were consistent with the results of stamping test.The results showed replicated the distortion phenomenon successfully through experimental dies.And it provided the basis to investigate the root-cause of draw die related surface low and distortion.