铝合金汽车车门冲压成形工艺研究

发布时间：2018-09-06 16:16

【摘要】：因汽车覆盖件有其自身特点,所以覆盖件冲压成形与一般冲压成形不同,也一直在研究领域被归为一种特殊的冲压成形工艺。覆盖件的成形质量受其拉深成形过程中的变压边力控制技术的影响非常大,世界各国的学者和工程师都在不断的努力,使得覆盖件拉深成形变压边力技术研究的深度和广度都取得了很大进展,然而直至今天,变压边力控制技术仍未能在工业界得到广泛应用。本文以汽车车门零件为研究对象,以铝合金板材为主要材料,通过数值模拟及实验分析,系统研究了铝合金车门的冲压成形特点及其影响因素。在对汽车覆盖件用铝合金板的冲压成形性能检验时,主要是通过铝合金半球形件冲压成形数值模拟与实验。在汽车车门数值模拟方面,通过车门实物扫描,得到了车门的扫描数学模型,经过数据处理得到简化后的数学模型。通过确定冲压方向、工艺补充设计最终得到了数值模拟用有限元模型,通过设定不同压边力数值我们得到了没有拉延筋时的仿真分析结果,研究压边力对成形结果的影响。之后,通过建立不同拉延筋的数学模型再进行车门的仿真模拟,研究拉延筋对冲压成形的影响,最后研究了工艺切口或工艺孔对铝合金板材冲压成形的影响。本章研究为压边力、拉延筋及工艺切口或工艺孔等对铝合金覆盖件板材冲压成形影响分析提供了参考。车门模具的设计是由仿真成形结果决定的,然后判断冲压成形结果跟仿真的匹配程度,做进一步的研究。在汽车车门实验方面,采用120t油压机进行实验,在实验中安装了压力传感器及位移传感器,用于测定冲压过程中压边力与位移的关系变化。通过实验分析,验证了前面数值模拟分析的结果,验证了压边力、拉延筋及工艺切口对冲压成形结果的影响,为进一步研究铝合金覆盖件冲压成形提供了实验基础。
[Abstract]:Because the automobile panel has its own characteristics, the panel stamping forming is different from the general stamping forming, and has always been classified as a special stamping forming process in the field of research. The forming quality of the panels is greatly affected by the variable blank holding force control technology in the process of deep drawing, and scholars and engineers all over the world are making continuous efforts. Great progress has been made in the depth and breadth of the research on the blank-holder force of the deep drawing deformation of the panel. However, up to now, the control technology of the variable blank holding force has not been widely used in industry. Taking automobile door parts as the research object and aluminum alloy sheet as the main material, this paper systematically studied the forming characteristics and influencing factors of aluminum doors by numerical simulation and experimental analysis. In the process of testing the stamping formability of aluminum alloy sheet used for automobile panels, the numerical simulation and experiment of stamping forming of aluminum alloy hemispherical parts are carried out. In the aspect of numerical simulation of automobile door, the scanning mathematical model of the door is obtained through the physical scanning of the door, and the simplified mathematical model is obtained by data processing. The finite element model for numerical simulation is obtained by determining the direction of stamping and the finite element model is obtained. By setting different blank holder forces, we obtain the results of simulation analysis without drawing bars, and study the influence of blank holder force on the forming results. After that, the influence of drawing bars on stamping forming is studied by establishing different mathematical models of drawing bars and then simulating the door. Finally, the effects of process cuts or process holes on the stamping forming of aluminum alloy sheet are studied. This chapter provides a reference for the analysis of the influence of blank holder force, drawing bars, process cuts or process holes on the sheet metal forming of aluminum alloy panels. The design of the door die is decided by the simulation result, then the matching degree between the stamping forming result and the simulation is judged, and further research is done. In the car door experiment, 120 t hydraulic press was used to carry out the experiment. The pressure sensor and displacement sensor were installed in the experiment, which was used to measure the change of the relation between the blank holder force and the displacement during the stamping process. Through experimental analysis, the results of numerical simulation are verified, and the influence of blank holder force, drawing bar and cutting on stamping results is verified, which provides an experimental basis for further research on stamping forming of aluminum alloy panel.
【学位授予单位】：湖北工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：U466;TG389

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