U型调整垫冲裁数值模拟

发布时间：2018-06-19 15:31

本文选题：冲裁 + 间隙　；参考：《吉林大学》2015年硕士论文

【摘要】：近年来随着国内外轨道车辆制造行业的飞速发展，轨道车辆的车体制造技术和产品质量也越来越受到国内外制造行业的关注。考虑到车体的质量和制造精度等问题，我国轨道车辆的车体大多为铝合金车体和不锈钢车体。其中，车体中一个重要的构件就是调整垫，车体调整垫用来调节车体中机械器件的高度、零件间的间隙及各个构件的连接，其质量好坏直接影响轨道车辆的后序装配工作。车体调整垫加工属于冲孔类的冲裁加工工艺，因此对冲裁技术的研究是至关重要的。现阶段，经冲裁工艺加工完的冲裁件依旧存在较多缺陷，主要有制件表面不平整、断面质量差、毛刺较大等问题，这些问题不仅降低了实际生产的效率，同时增加了后续工序；除了需要解决断面质量差、毛刺较大的问题之外，还需对调整垫通用冲模进行开发研究，过度的更换模具是一种无辜的消耗，开发调整垫通用模具即降低成本又提高生产效率。本文对以上现实中存在的两大难题应用DEFORM-3D软件进行模拟研究，具体内容如下：（1）首先对调整垫在冲裁过程中裂纹的产生、扩展及断裂过程进行模拟分析；其次对板厚为2mm的铝合金5083-O和不锈钢301L-ST的U型调整垫冲裁过程进行数值模拟研究，分析了凸凹模间隙对冲裁断面质量的影响，确定合理的凸凹模间隙范围及最优冲裁间隙值。2mm厚铝合金5083-O的合理凸凹模间隙（双边间隙）范围是3%t~5%t（0.06mm~0.1mm），最优冲裁间隙值为3%t（0.06mm）；2mm厚不锈钢301L-ST的合理凸凹模间隙范围是5%t~7%t（0.1mm~0.14mm），最优冲裁间隙值为5%t。同时将上述两种材料的模拟结果做对比，研究材料性能对冲裁断面各部分比例的影响。（2）研究凸模与压料板间隙对冲裁断面质量的影响，确定最优凸模与压料板的间隙值使冲裁断面质量最优。2mm板厚的铝合金5083-O调整垫，，在凸、凹间隙为0.06mm（3%t）、凸模与压料板间隙为0.05mm时得到的冲裁件断面质量最优。（3）结合数值模拟技术，探究U型调整垫通用冲模开发的可行性；研究采用一种通用冲裁模具，在相同工艺参数下实现对不同板厚调整垫的冲裁加工。研究结果表明0.5mm和1mm的铝合金5083-O板料可在冲裁间隙为0.02mm的同一套模具上进行冲裁；板厚为1.5mm、2mm、2.5mm和3mm的铝合金5083-O板料可在冲裁间隙为0.075mm的同一套模具上进行冲裁；板厚为4mm和5mm的铝合金5083-O板料可在冲裁间隙为0.36mm的同一套模具上进行冲裁。此外，板厚为0.5mm和1mm的不锈钢301L-ST板料可在冲裁间隙为0.02mm的同一套模具上进行冲裁；板厚为1.5mm、2mm、2.5mm和3mm的不锈钢301L-ST板料可在冲裁间隙为0.105mm的同一套模具上进行冲裁；板厚为4mm和5mm的不锈钢301L-ST板料可在冲裁间隙为0.36mm的同一套模具上进行冲裁。在上述数值模拟研究的基础上，本文开展了车体U型调整垫冲裁实验研究，验证了最优间隙选取值的准确性和通用模具开发的可行性。本文确定的凸凹模间隙最优值和调整垫通用模具开发技术已应用于长春轨道客车U型调整垫的生产中，反馈效果良好。
[Abstract]:In recent years, with the rapid development of the manufacturing industry of rail vehicles both at home and abroad, the manufacturing technology and product quality of rail vehicles are becoming more and more concerned about the manufacturing industry at home and abroad. Considering the quality and manufacturing precision of the car body, the body of our rail vehicles is mostly aluminum alloy car body and stainless steel car body. An important component is the adjustment pad, the body adjustment pad is used to adjust the height of the mechanical device in the body, the gap between parts and the connection of each component. Its quality directly affects the post sequence assembly work of the rail vehicle. The processing of the body adjustment pad belongs to the punching processing technology of the punching type. Therefore, the research on the cutting technology is of great importance. Yes.
At the present stage, there are still many defects in blanking parts processed by blanking process, such as uneven surface of the workpiece, poor quality of cross section, large burr, and so on. These problems not only reduce the efficiency of the actual production, but also increase the follow-up process. Besides the problems that need to solve the problem of poor cross section quality and large burr, the adjustment cushion is also needed. General die for the development and research, excessive replacement of the die is an innocent consumption, the development of the adjustment pad general mold is to reduce costs and improve production efficiency. This paper in the above two major problems existing in the application of DEFORM-3D software simulation research, the specific content as follows:
(1) first, the process of crack generation, expansion and fracture in the blanking process is simulated and analyzed. Secondly, the numerical simulation study on the blanking process of aluminum alloy 5083-O and stainless steel 301L-ST of 2mm plate thickness is carried out. The influence of the gap gap on the quality of the gap is analyzed, and the reasonable clearance range of the convex and concave die is determined. The reasonable gap (bilateral gap) range of.2mm thick aluminum alloy 5083-O is 3%t~5%t (0.06mm~0.1mm) and the optimal blanking gap is 3%t (0.06mm), and the reasonable gap range of 2mm thick stainless steel 301L-ST is 5%t~7%t (0.1mm~0.14mm), and the best blanking clearance value is the analog knot of the two kinds of materials. The effect of material properties on the proportion of each part of the cutting section is studied.
(2) study the influence of the gap between the punch and the blanking plate, and determine the gap between the best punch and the press plate to make the aluminum alloy 5083-O adjusting pad with the best.2mm plate thickness for the cutting section, and the gap is 0.06mm (3%t) in the convex, concave gap and the gap between the punch and the press plate is 0.05mm.
(3) combining with the numerical simulation technology, the feasibility of the development of the general punching die for the U type adjustment pad is explored. A general blanking die is used to realize the blanking processing of different plate thickness adjusting pads under the same process parameters. The results show that the aluminum alloy 5083-O plate of 0.5mm and 1mm can be washed on the same die with the blanking gap of 0.02mm. The aluminum alloy 5083-O sheet with plate thickness of 1.5mm, 2mm, 2.5mm and 3mm can be blanked on the same set of die with the blanking gap of 0.075mm, and the aluminum alloy 5083-O plate with the thickness of 4mm and 5mm can be blanked on the same die with the blanking gap of 0.36mm. In addition, the stainless steel plate with the thickness of 0.5mm and 1mm can be blanked in the blanking gap. In the same set of die for 0.02mm, the stainless steel 301L-ST board with a thickness of 1.5mm, 2mm, 2.5mm and 3mm can be blanked on the same die with the blanking gap of 0.105mm, and the stainless steel 301L-ST board with the thickness of 4mm and 5mm can be blanked on the same set of die with the blanking gap for 0.36mm.
On the basis of the above numerical simulation research, this paper has carried out the research on the U type adjustment pad blanking experiment of the car body, which verifies the accuracy of the optimal gap selection and the feasibility of the universal die development.
The optimal value of the gap between the die and the concave die and the development technology of the adjustment pad have been applied to the production of the U type adjustment pad of Changchun railway passenger car, and the feedback effect is good.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG386.2

【参考文献】