支撑板冲压成形模具磨损分析及优化

以某支撑板冲压成形为研究对象,基于Archard磨损理论,采用有限元分析软件DEFORM-3D对其冲压成形过程中出现的模具磨损进行模拟分析,探索了其磨损原因;为最大化模具使用寿命,采用正交试验对影响模具磨损的工艺参数进行优选。选取冲压速度、摩擦系数、模具硬度、压边力作为因素,设计4因素4水平的正交试验,通过对试验结果进行极差和方差分析,得出各因素对结果的影响趋势,综合考虑后确定最优参数组合为:冲压速度为5 mm·s^-1、摩擦系数为0.12、模具硬度为64 HRC、压边力为280 kN,同时,根据模拟结果对模具使用寿命进行预测。采用优化后的参数进行试模,发现模具的使用寿命与模拟结果基本一致,模具使用寿命大幅延长,验证了有限元分析结果的正确性。

Wear analysis and optimization of stamping die for support plate

Taking the stamping of a support plate as the research object,the wear of die during the forming process was analyzed based on Archard wear theory by finite element analysis software DEFORM-3D.The reason of wear was analyzed.In order to maximize the service life of die,the stamping speed,the friction coefficient,the die hardness and the blank holder force were chosen as process parameters,and the four-factor and four-level orthogonal test was designed to optimize the process parameters.Through the range analysis and variance analysis of the orthogonal test results,the influence trend of each factor on the results was obtained.Furthermore,the optimal parameters was determined as the stamping speed of 5 mm·s^-1,the friction coefficient of 0.12,the die hardness of 64 HRC and the blank holder force of 280 kN.At the same time,the service life of was predicted by simulation results.The test was conducted by the optimized parameters.It shows that the service life of die is greatly extended by the optimized parameters and it has a good consist with the simulation results,which verifies the correctness of the finite element analysis results.