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通过对某车型半截式行李箱外板模具开发中遇到的钣金缺陷问题分析,揭示了材料成形中的某些基本规律。鉴于CAE在该问题分析上存在不足,采用塑性力学、工艺学和CAE相结合的方法,探索产生波纹缺陷的根本原因,分析表明,冲压方向上的弦高投影过大是产生变形的根源,而加工硬化是克服变形的难点。借鉴理论分析的结论,制定出有针对性的优化方案,不仅消除了波纹缺陷,还提高了材料利用率。优化后的工艺方案在新项目中得到了成功验证,零件材料利用率提升11%,单件成本降低7.93元。
Through the analysis of the sheet metal defects encountered in the mold development of a car’s semi-trunk suitcase, some basic laws in the material forming are revealed. In view of the shortcomings of CAE in the analysis of the problem, the mechanics and CAE are combined to explore the root causes of ripple defects. The analysis shows that the projection of the chord height in the stamping direction is the source of deformation, Work hardening is to overcome the difficulties of deformation. Reference to the conclusions of theoretical analysis, to develop a targeted optimization program, not only eliminates the ripple defects, but also improve the material utilization. The optimized process scheme has been successfully verified in the new project. The utilization of parts and materials has been increased by 11% and the cost per piece has been reduced by RMB 7.93.