汽车前纵梁内板冲压成形仿真及回弹补偿的研究.doc

汽车前纵梁内板冲压成形仿真及回弹补偿的研究

汽车前纵梁内板冲压成形仿真及
回弹补偿研究
重庆大学硕士学位论文
(学术学位)学生姓名: 吴善冬
指导教师: 周杰教授
专业:材料加工工程
学科门类:工学
重庆大学材料科学与工程学院
二 O 一三年五月
Study on Forming Simulation and
pensation of The
Front-carling Inner Plate A Thesis Submitted to Chongqing University
in Partial Fulfillment of the Requirement for the
Master’s Degree of Engineering
By
Wu Shandong
Supervised by Prof. Zhou Jie
Specialty: Material Processing EngineeringCollege of Material Science and Engineering ofChongqing University, Chongqing, China
May, 2013 重庆大学硕士学位论文中文摘要
摘要
汽车前纵梁内板零件是一个典型的 U 形件,它的形状复杂、截面高度变化剧
烈、表面质量要求高, 且具有局部成形的特点。前纵梁内板一般采用冲压成形方
式制造,其生产效率高,产品质量比较稳定,可自动化生产作业。
本文以某型汽车的前纵梁内板为研究对象, 利用板料冲压成形有限元软件
DYNAFORM 对其拉延、卸载回弹、修边、回弹及回弹补偿等进行了有限元数值
模拟仿真和实验研究。主要内容如下:①建立了前纵梁内板的有限元仿真模型,对此零件的拉延冲压成形的过程进
行了有限元数值模拟仿真。通过分析,对前纵梁内板几何模型的局部结构进行了
优化,破裂缺陷得以消除;
②以压边力、模具间隙、摩擦系数、冲压速度作为考察因素,采用正交试验
设计方法进行实验,分析了各个工艺参数对前纵梁内板成形的厚度和回弹程度的
影响,并找出了成形效果最好的一组工艺参数。
③基于对其回弹的仿真计算,应用 LS-DYNA 有限元数值模拟仿真分析软件,
实现对回弹的自动补偿,通过迭代算法对模具形状不断修正使得最后成形的零件
在回弹后恰好满足设计形状要求,对指导工程实际生产有重要意义。
关键词: 前纵梁内板, 回弹, 回弹补偿, 优化,仿真I 重庆大学硕士学位论文英文摘要
ABSTRACT
The Front-carling Inner Plate is a typical U-shaped pieces. Its change of section
height is rapidly which has a high surface quality requirements and plex shape. In
addition ,it exists local shaping feature. The Front-carling Inner Plate monly
manufactured by metal forming. It can be automated production ,owing to its height
production efficiency and the production with a rather stable qualityTook the Front-carling Inner Plate of a new-style car as the object of the study ,the
research of the drawing 、trimming deflashing 、spring back calculation and spring back
compensation were done with the finite element software Dynaform. The primary
contents are as follows:
①The finite element simulation model of the Front-carling Inner Plate was builtThe stamping process was simulated ,and the further optimization of its partial 3D
model was done to prevent its fracture defect
②Tak