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针对某车型超高强钢零件前围板中间横梁存在的成形起皱开裂、回弹过大以及边部付型问题,借助于有限元软件AUTOFORM对原工艺方案进行了全流程仿真,并对问题原因进行分析,提出了一种优化工艺方案,并采用AUTOFORM软件从成形、减薄、回弹等方面对新方案进行了评估。结果表明:优化后的工艺方案最大减薄率减小约4%,同时边部付型良好,基本与产品边界一致;零件上的最大回弹值为1.21 mm,较优化前减小1倍,且呈对称分布;同时,零件在端部法兰位置的起皱基本消失,并从零件实冲结果得以验证。提出的优化工艺方案能够保证零件成形的充分性,回弹得到改善,且一步成形到底的方式边部付型更好,解决了原方案存在的问题,该方法可用于指导其他超高强钢零件的应用。
Aiming at the problems such as forming wrinkle cracking, excessive rebound and edge payoff problem in the middle crossbeam of dash panel of a high strength steel part of a vehicle, the whole process simulation of the original process plan is carried out by means of the finite element software AUTOFORM. Analyzed and proposed an optimized process plan, and used AUTOFORM software to evaluate the new plan from aspects of forming, thinning and springback. The results show that the maximum reduction rate of the optimized process scheme is reduced by about 4% and the marginal pay is good, which is basically consistent with the product boundary. The maximum rebound value of the part is 1.21 mm, which is 1 times lower than that before optimization. And symmetrical distribution; at the same time, the parts in the end of the flange position of the wrinkles basically disappeared, and from the part of the actual results to be verified. The proposed optimization process scheme can ensure the adequacy of part forming, improve the rebound, and the one-step forming in the end way to pay the better side to solve the original program problems that can be used to guide the other ultra-high strength steel parts application.