某汽车燃料箱隔热板翻边成形工艺设计及研究

目的为了成形高质量、少缺陷的汽车燃油箱隔热板。方法采用整体翻边-局部反拉深的工艺方法,以隔热板曲面凸台圆角处的最大减薄率为试验指标,采取正交试验及极差分析确定最优成形工艺参数,并利用有限元数值软件对其成形过程进行模拟。结果各因素对曲面凸台圆角减薄的影响主次顺序为:凸模下压速度、摩擦因数、凸模与顶出块夹紧力,最优成形工艺参数组合为:下压速度为10 mm/s、摩擦因数为0.12、夹紧力为40 kN。由等效应变结果分析得出,随着变形量的增加,左侧翻边曲面等效应变分布大于右侧,两侧翻边曲面交接处也积累了较大应变。实际成形件的最大减薄率为凸台位置的17.1%,满足生产要求。结论在最优工艺参数下生产出合格隔热件,实际成形件的减薄情况与模拟结果基本一致,验证了模具设计和模拟的准确性,这对于成形结构复杂的异形构件具有一定的指导意义。

Design and Study of Flanging and Forming Process of Automotive Fuel Tank Insulation Panel

The work aims to form high-quality automotive fuel tank insulation panel with fewer defects. The process method of integral flanging and local back drawing was adopted, and the maximum thinning rate at the rounded corner of the heat shield surface bump was taken as the experimental index. The optimal forming process parameters were determined by orthogonal test and range analysis, and the forming process was simulated by finite element numerical software. The order of effect of each factor on fillet thinning of curved boss was as follows:punch lowering speed, friction coefficient, and clamping force between punch and ejection block. The optimal combination of forming process parameters was as follows:press speed of 10 mm/s, friction coefficient of 0.12, and clamping force of 40 kN. According to the analysis of equivalent strain results, with the increase of deformation, the equivalent strain distribution of the left flanging surface was greater than that of the right, and the junction of the two flanging surfaces also accumulated a large strain. The maximum thinning rate of the actual forming part was 17.1% of the boss position, which met the production requirements. The qualified heat insulation parts can be produced under the optimal process parameters, and the thinning of the actually formed parts is basically consistent with the simulation results, which verifies the accuracy of the mold design and simulation and has certain guiding significance for forming the shaped components with complex structures.