基于Autoform的汽车天窗加强环成形模拟及工艺优化

以某型号汽车天窗加强环为研究对象,通过对其结构进行分析,初步设计冲压工艺为拉延→修边、冲孔→修边、冲孔→翻边,初选压边力、摩擦系数、拉延筋阻力系数、工艺补充等参数,并利用Autoform进行数值模拟。根据模拟结果中所出现的起皱、减薄、开裂等缺陷,并结合产品结构,调整压边力、摩擦系数以及拉延工艺以得到符合实际生产的工艺参数、冲压工艺。最终确定的工艺参数为:压边力为2400 kN、凸凹模间隙为1.2 mm、摩擦系数为0.15;冲压工艺为:拉延→修边、冲孔→修边、冲孔→翻遍、整形→冲孔。根据确定的工艺参数进行成形实验,得到了合格的零件,有效地降低了模具的设计成本。

Forming simulation and process optimization on automobile skylight reinforcement ring based on Autoform

For the skylight reinforcement ring of a certain model automobile,its stamping process was preliminarily designed as drawing→trimming,punching→trimming,punching→flanging by analyzing its structure.Then,the parameters,such as blank holder force,friction coefficient,drawbead resistance coefficient and process supplement,were preliminarily selected,and its forming process was numerically simulated by Autoform.According to the wrinkling,thinning,cracking and other defects in the simulation results and the structure of product,the blank holder force,friction coefficient and drawing process were adjusted to obtain the process parameters and stamping process that were in line with the actual production.Finally,the process parameters were determined as follows the blank holder force of 2400 kN,the clearance between punch and die of 1.2 mm and the friction coefficient of 0.15,and the stamping process was designed as drawing→trimming,punching→trimming,punching→flanging,shaping→punching.According to the determined process parameters,the forming experiment was conducted,and the qualified parts were obtained to reduce the design cost of mold effectively.