锻压技术

复杂截形高强钢闭口防撞梁成形及回弹研究

英文标题：Research on forming and springback of closed anti-collision beam for high-strength steel with complex cross-section

作者：曹大兴高亚南王吉彬吴玉慧刘阳

单位：凌云工业股份有限公司

关键词：复杂截形高强钢防撞梁回弹起皱

分类号：TG386

出版年,卷(期):页码：2019,44(6):154-161

摘要：

针对具有复杂截面结构的零件在其成形过程中回弹量难以控制的问题，采用数值模拟和实验的方法，对具有复杂截形的DP980高强钢闭口防撞梁进行成形及回弹特性研究。通过对比设计角度、成形角度、回弹后工件角度得出了回弹角、过弯角、设计角度误差之间的关系；通过分析成形后的应力、应变分布，得出了开裂风险及起皱区域；通过回弹前后的应力、应变分布对比，得出了回弹发生的主要位置及应力释放的变化规律；通过测量实验防撞梁的成形角度、褶皱凹坑尺寸及中心距，并对比仿真结果，验证了仿真的准确性。研究表明：复杂截形高强钢闭口防撞梁回弹较为严重，回弹角为2.2°，占成形角的17%；回弹后边缘位置应力释放，残余应力主要集中在弧形区域内部；回弹后内弧面存在起皱现象，褶皱深度为2 mm，褶皱中心距为48 mm，外弧面无拉裂风险；经三坐标测量机测量实际制成的工件成形角度10.1°与设计角度7.8°相差2.3°，回弹较难控制。

For the problem that the springback of part with complex cross-section structure is difficult to control in the forming process, the forming and springback characteristics of closed anti-collision beam with complex cross-section for high-strength steel DP980 were studied by numerical simulation and experiment. The relationship among springback angle, over-bending angle and design angle error was obtained by comparing the design angle, forming angle and workpiece angle after springback. By analyzing the distribution of stress and strain after forming, the crack risk and wrinkle areas were obtained. By comparing the distribution of stress and strain before and after springback, the main location of springback and the variation of stress release were obtained. Furthermore, the accuracy of the simulation was verified by comparing the forming angle of experimental anti-collision beam,the size and center distance of fold pit with the result of simulation. The results show that the springback of closed anti-collision beam with complex cross-section for high strength steel is serious, and the springback angle is 2.2°, which is 17% of the forming angle. After springback, the stress is released at the edge, and the residual stress mainly concentrates in the arc area. After springback, there are wrinkles on the inner arc surface with the depth of 2 mm, the distance between the centers of wrinkles is 48 mm, and there is no risk of tension cracks on the outer arc surface. Thus, it is difficult to control the springback of the workpiece with the actual forming angle of 10.1° measured by CMM, which is 2.3° different from the design angle 7.8°.

基金项目：

曹大兴(1990-)，男，硕士，工程师 E-mail：caodaxing@lygf.com 通讯作者：高亚南(1984-)，男，博士，高级工程师

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