汽車覆蓋件回彈模擬精度的主因素分析
摘要
汽車覆蓋件的結(jié)構(gòu)復(fù)雜以及影響沖壓變形的因素之多，決定了其沖壓過(guò)程中變形規(guī)律的復(fù)雜性，分析起來(lái)十分困難。同時(shí)隨著汽車工業(yè)的發(fā)展，覆蓋件沖壓成形中回彈問(wèn)題變得越來(lái)越棘手己引起了世界汽車工業(yè)界和學(xué)術(shù)界的廣泛關(guān)注。目前回彈預(yù)測(cè)與控制的問(wèn)題已成為該領(lǐng)域的研究熱點(diǎn)與難點(diǎn)之一。
在回彈的研究工作中，國(guó)內(nèi)外研究的對(duì)象主要集中在彎曲零件上，對(duì)汽車覆蓋件之類復(fù)雜拉延件的回彈研究則較少，而覆蓋件的研究又主要集中在破裂和起皺方面。針對(duì)目前的研究現(xiàn)狀，本文使用有限元模擬軟件DYNAFORM，并結(jié)合彈塑性有限元方法對(duì)覆蓋件的回彈規(guī)律進(jìn)行了研究。
首先對(duì)汽車覆蓋件及其沖壓成形中變形的特點(diǎn)進(jìn)行了歸納，介紹了回彈預(yù)測(cè)方法的發(fā)展歷史以及國(guó)內(nèi)外學(xué)者在這些方面做出的成就，指出了有限元數(shù)值模擬是目前回彈預(yù)測(cè)的非常有效的方法。其次，對(duì)覆蓋件沖壓數(shù)值模擬的關(guān)鍵技術(shù)及其理論進(jìn)行了探討研究與總結(jié)，闡述了在回彈研究中所采用的建模方法和計(jì)算方法，同時(shí)分析了覆蓋件成形回彈模擬中材料參數(shù)、壓邊力對(duì)回彈模擬精度的影響。
以典型的覆蓋件為例，實(shí)現(xiàn)了成形過(guò)程以及回彈的數(shù)值模擬。分別研究了壓邊力、材料的楊氏模量對(duì)于覆蓋件成形及回彈的影響。研究結(jié)果表明：回彈量隨壓邊力、楊氏模量的增大而增大。
利用DYNAFORM對(duì)汽車翼子板的成形及回彈進(jìn)行了模擬，表明DYNAFORM模擬軟件對(duì)回彈的預(yù)測(cè)具有很大的實(shí)用價(jià)值。最后利用ISIGHT軟件分析回彈與壓邊力、楊氏模量的數(shù)學(xué)關(guān)系。

關(guān)鍵詞：DYNAFORM；主因素分析；模具；ISIGHT

 
Analysis of Main Factors on Accuracy of Springback Simulation for Automobile Panel
Abstract
Automobile parts stamping deformation of complex structure and the factors that affect many, determine its deformation during stamping the complexity of analysis is extremely difficult. At the same time as the automobile industry, Stamping become increasingly difficult in the spring issue has attracted the world's automotive industry and academic attention. Springback Prediction and Control of the current issue has become a hot research topic and one of the difficulties.
In the spring of the research work, mainly focused on domestic and international research on the curved part of the class of automobile panel drawing complex parts of the less resilient, and covering parts of the study also focused on break and play wrinkled areas. For the current study, this paper uses finite element simulation software DYNAFORM, combined with elastic-plastic finite element method panel studying the pattern of rebound.
First of all, the car of the panels and metal forming deformation characteristics were summarized, introducing the history of development of Springback Prediction Method scholars at home and abroad the achievements made in these areas, pointing out that the finite element numerical simulation is the prediction of springback very effective. Secondly, numerical simulation Stamping key technology research and theory are discussed and summarized the study described in the spring used in modeling and calculation methods, it analyzes the panel forming and springback simulation material parameters , blank holder force on the springback simulation accuracy.
A typical panel, for example, to achieve the forming process and springback simulation. Each of the blank holder force, the material Young's modulus for panel forming and springback. The results show that: springback with the blank holder force, Young's modulus increases.
Use of the automobile fender DYNAFORM forming and springback simulation that DYNAFORM springback prediction simulation software has great practical value. Finally, software analysis ISIGHT rebound and blank holder force, the mathematical relationship between Young's modulus

Key words: DYNAFORM; main factors analysis; die; isight

目錄
1 緒論 5
1.1 引言 5
1.2 汽車覆蓋件的變形特點(diǎn)及其回彈 7
1.2.1 汽車覆蓋件的特點(diǎn) 7
1.2.2 汽車覆蓋件成形過(guò)程中的回彈 7
1.3 板料成形回彈問(wèn)題的發(fā)展及其研究現(xiàn)狀 8
1.3.1 解析研究 8
1.3.2 實(shí)驗(yàn)研究 9
1.3.3 有限元數(shù)值模擬方法 9
1.4 本文主要研究?jī)?nèi)容 10
2 汽車覆蓋件的沖壓工藝分析 11
2.1 汽車覆蓋件 11
2.1.1 對(duì)覆蓋件的要求 11
2.1.2 汽車覆蓋件沖壓工藝的特點(diǎn) 12
2.2 沖壓工藝的確定 12
2.2.1 沖壓方向的確定 12
2.2.2 合理增加工藝補(bǔ)充部分 13
2.2.3 正確培植壓料面形狀 14
2.2.4 汽車的翼子板 14
2.2.5 工藝分析 15
2.2.6 沖壓方向及工序 15
2.2.7 壓料面及工藝補(bǔ)充部分的設(shè)計(jì) 15
2.3 選用模具的類型及結(jié)構(gòu) 16
2.3.1 三種拉延模的比較 16
2.3.2 確定拉深模的類型 18
2.4 選用壓力機(jī) 18
2.4.1 采用雙動(dòng)壓力機(jī)的優(yōu)點(diǎn) 18
2.4.2 初步選定壓力機(jī) 18
3 汽車覆蓋仦的有限元分析 19
3.1 DYNAFOR 的幾個(gè)功能模塊 19
3.1.1 DYNAFORM的兠個(gè)刟能模坕 19
3.1.2 DYNAFORM求解器 20
3.1.3 DYNAOPM的后處理 20
3.2 DYNAFORM的仿真步驟 20
3.3 采用仿真技術(shù)的優(yōu)點(diǎn) 22
3.4 模具設(shè)計(jì)的有限元分析仿真與分析 23
3.4.1 參數(shù)初步確定 23
3.4.2 模型的建立 23
3.4.3 對(duì)零件進(jìn)行網(wǎng)格劃分 24
3.4.4 調(diào)整沖壓方向 26
3.4.5 創(chuàng)建壓料面和工藝補(bǔ)充部分 27
3.4.6 對(duì)壓料面進(jìn)行裁剪 29
3.4.7 毛坯形狀大小計(jì)算材料性質(zhì)特性 29
3.4.8 Draw Die模塊參數(shù)設(shè)置 29
3.4.9 成形缺陷的分析判斷 31
3.4.10 調(diào)整壓邊力與材料系數(shù)并作回彈計(jì)算 32
3.4.11 分析回彈結(jié)果 33
4 影響回彈的主因素分析 35
4.1 引言 35
4.2 回彈優(yōu)化分析 35
4.2.1 前期準(zhǔn)備 35
4.2.2 通過(guò)算法得到優(yōu)化結(jié)果 36
4.3 主因素分析 37
5 模具結(jié)構(gòu)設(shè)計(jì)的確定 38
5.1 結(jié)構(gòu)尺寸參數(shù) 38
5.2 凹模設(shè)計(jì) 39
5.2.1 凹模結(jié)構(gòu) 40
5.2.2 凹模壓料面寬度尺寸的確定 40
5.3 導(dǎo)向板 40
5.4 空氣孔 41
5.5頂件器頂件 42
5.6模具總裝圖 42
總結(jié) 44
參考文獻(xiàn) 45
致謝 46
附錄 47