汽车覆盖件模具快速设计方法研究

发布时间：2018-08-17 12:20

【摘要】：模具设计的速度与精度直接决定着汽车开发周期和质量。基于板料成形CAE分析的汽车覆盖件模具结构设计方法已广泛应用于汽车覆盖件模具制造厂商，可以在一定程度上提高产品的更新速度。面对复杂多变的市场环境和车身覆盖件的频繁更新，如何缩短工艺规划、模具结构设计与产品试制到最终的批量生产的时间决定着产品市场竞争力与企业的核心竞争力，是企业越来越看重的问题。在板料成形CAE分析过程中，尤其是对回弹问题的分析过程中，摩擦力、压边力、拉延筋尺寸等参数的相互影响与制约增加了工艺规划的难度。所以，组合参数的选取对研究回弹问题有着重要意义。本文介绍了板料成形有限元分析和汽车板成形技术的研究背景，在研究覆盖件产品工艺规划和拉延模具结构设计方法的基础上，结合某车型顶盖后横梁，提出了基于组合参数优化的汽车板精益成形分析和使用同步建模快速设计拉延模具结构的理念，主要包括以下几方面内容：阐述了汽车板成形仿真理论的关键技术，包括物理关系（本构理论）、有限元求解过程算法、单元模型和接触搜索与摩擦处理这四部分核心内容，，并借助AutoForm一步逆成形模块完成了成形预评估和毛坯尺寸的初步确定。并归纳了模面造型设计的流程，进行了汽车顶盖后横梁的冲压工艺初步设计和仿真前处理的设置。使用AutoForm软件对顶盖后横梁产品进行全工序成形分析。通过正交试验研究了摩擦因子、拉延筋、压边力和模具间隙等成形参数的组合对产品回弹数值和减薄率的影响。使用方差分析法得出上述因素对成形质量影响的程度，选出最佳优化工艺组合，在此基础上设计出综合冲压工序图。归纳总结了顶盖横梁类拉延模具结构特点，结合汽车顶盖后横梁综合冲压工艺图，借助三维造型软件，设计出汽车顶盖后横梁的拉延模具，系统阐述了该拉延件产品的完整设计流程，并详细介绍了模具结构校核的要点。
[Abstract]:The speed and precision of die design directly determine the development cycle and quality of automobile. The design method of automobile panel die structure based on sheet metal forming CAE analysis has been widely used in automobile panel die manufacturers, which can improve the renewal speed of products to a certain extent. Faced with the complex and changeable market environment and the frequent renewal of body panels, how to shorten the process planning, the time between die structure design and product trial production to the final batch production determines the market competitiveness of products and the core competitiveness of enterprises. It is an increasingly important issue for enterprises. In the process of CAE analysis of sheet metal forming, especially in the analysis of springback problem, the mutual influence and restriction of friction force, blank holder force and drawing bar size increase the difficulty of process planning. Therefore, the selection of combination parameters is of great significance to the study of springback problem. This paper introduces the finite element analysis of sheet metal forming and the research background of automobile sheet forming technology. On the basis of studying the process planning of panel products and the design method of drawing die structure, combined with the rear crossbeam of the top cover of a certain vehicle model, the paper introduces the research background of sheet metal forming finite element analysis and automobile sheet forming technology. The concept of lean forming analysis based on combination parameter optimization and rapid design of drawing die structure using synchronous modeling are put forward. The main contents are as follows: the key technology of automobile sheet forming simulation theory is expounded. It includes four core parts: physical relation (constitutive theory), finite element algorithm, element model and contact search and friction treatment. The pre-evaluation and the initial determination of blank size are completed with the help of AutoForm one-step inverse forming module. The process of die surface modeling design is summarized, and the preliminary design of stamping technology and the setting of simulation pre-processing are carried out. The AutoForm software is used to analyze the whole process of the cross beam product behind the top cover. The effects of friction factor, drawing bar, blank holder force and die clearance on the springback and thinning rate of the product were studied by orthogonal test. The degree of influence of the above factors on the forming quality was obtained by using variance analysis method, and the optimum process combination was selected, and the comprehensive stamping process diagram was designed on this basis. This paper summarizes the structural characteristics of the drawing die of the roof beam, combined with the comprehensive stamping process diagram of the rear cross beam of the top cover of the automobile, and with the aid of 3D modeling software, designs the drawing die for the rear beam of the top cover of the automobile. The complete design flow of the drawing part is systematically expounded, and the main points of die structure checking are introduced in detail.
【学位授予单位】：沈阳工业大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG385

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