制动毂挡尘盖拉深成形过程的应力应变分析

在大型CAD软件Pro/E中建立了汽车车轴制动毂挡尘盖拉深成形的凸凹模模型,运用大型商用有限元软件MSC.Marc,对其拉深成形过程进行了数值模拟.分析金属材料在拉深时的流动情况及挡尘盖在拉深后的应力应变分布规律,重点研究了压边力和凸凹模间隙对板材成形性能的影响,分析了起皱和破裂产生的原因、特点、影响因素以及预防措施等.模拟及试验结果表明,工件在拉深时,凸缘部分材料易产生失稳起皱现象;凸、凹模之间的间隙是影响盒形部分产生破裂的主要原因.当刚性压边圈与凹模之间的间隙减小到1.2倍的料厚时,能获得表面质量光滑的合格件;当凸凹模及浮动凸凹模之间的间隙大于料厚时,能确保拉深过程顺利进行.

Analysis of stress and strain on deep drawing process of breaking-hub dust-cover

The models of the punch and die for the deep drawing process of the dust cover used in automotive axle breaking hub was established by CAD software, Pro/E, and then the deep drawing process was carried out by the FEA software, MSC. Marc. The metal flowing during drawing and the distributions of the stress and strain after drawing were studied, the effect of the blank holdering force and the clearance between the punch and die on the forming property were mainly investigated. The reasons, characteristics, influence factors and prevention measures of the fracture and wrinkle were analyzed. Both the simulation and experiment results show that, wrinkle occurs easily in the flange region, and the clearance between the punch and die is the main factor to influence the fracture. When the clearance between the rigid blank holder and die is less than 1.2 times of blank thickness, the workpiece with smooth surface quality can be obtained. when the clearance between the punch-die and the floating punch-die is greater than the blank thickness, the deep drawing process would be proceeded successfully.