复杂汽车零件多工位级进模全工序数值模拟

以某复杂汽车零件为研究对象,分别采用有限元逆算法的一步法和多步法对零件进行展开获取初始板料轮廓线,运用Autoform软件对零件的冲压成形过程进行全工序数值模拟。通过数值模拟,预测了产品成形过程中可能出现的开裂、起皱、回弹等缺陷,并对成形方案进行了修正;针对模拟结果反映的轮廓线误差问题,采用试错法对零件的修边线进行优化。确定了该汽车零件的最终成形工艺方案,并通过实际冲压结果验证了该冲压工艺方案的可行性。

Numerical simulation of whole process for multi-station progressive die of complex automotive structure parts

For a complex automotive structure parts, one-step method and multi-step method of the finite element inverse algorithm were adopted respectively to expand the part and obtain the initial blank outline, and the whole stamping process of the part was simulated by Autoform software. Then, possible forming defects, such as cracking, wrinkle, springback and others, were predicted by the numerical simulation, and the forming process project was modified. Then, for the contour error in simulation results, the trimming line was opti-mized by trial-and-error method, and the final forming process of the part was determined. Thus, the practical stamping results prove the feasibility of this method.