后背门内板成形工艺缺陷分析与优化

以汽车后背门内板为研究对象,根据零件形状起伏变化较大且拉深较深的特点,拟定了4道工序成形工艺方案。利用AutoForm软件对成形工艺方案进行数值模拟,分析拉深过程中零件右上角部位出现的拉裂现象、尾灯附近处存在起皱风险、法兰面有较大回弹量、局部变薄等缺陷,并提出通过加大开裂处R角半径、优化压料面及修改拉延筋减少起皱、在回弹量大的法兰面增加加强筋等措施。结果表明,优化后的后背门内板工艺方案在成形过程中无起皱、开裂缺陷,与数值模拟结果一致,验证了数值模拟分析的正确性。

Analysis and optimization on defects from forming process of back door inner panel

For the inner plate of the back door, a four-step process was developed based on the characteristics of the large change in parts shapes and the deep drawing.Then, the forming process was simulated by the AutoForm software, and the defects such as crack at the upper right corner of the site, wrinkling near the tail risk, large springback of flange surface and local thinning in the drawing process of parts were analyzed.Furthermore, solutions such as increasing the R corner radius, optimizing and modifying drawbeads to reduce wrinkle and increasing drawbeads on the big flange surface were proposed.The results show that there is no wrinkling and cracking in the forming process of the inner plate of the back door, which is consistent with the numerical simulation results.The correctness of analysis results is proved by the corresponding experiments.