锻压技术

汽车后桥壳冲压成形分析及实验研究

英文标题：Stamping analysis and experimental study on automobile rear axle housing

作者：胡义华柳明黄志超涂林鹏黄薇张永超

分类号：TH164

出版年,卷(期):页码：2020,45(7):71-88

摘要：

针对汽车后桥壳实际冲压成形中存在的缺陷，基于DYNAFORM软件对后桥壳冲压成形过程进行数值模拟，分析了压边力、冲压速度对冲压成形的影响。设计了正交实验优化工艺参数，以最大减薄率为评价指标，选取冲压速度、压边力、摩擦系数、凹凸模间隙为因素。结果表明，各因素对最大减薄率影响的主次关系依次为冲压速度、摩擦系数、压边力、凹凸模间隙。最优成形工艺参数为：冲压速度为1000 mm·s-1、压边力为300 kN、摩擦系数为0.12、凹凸模间隙为6.2 mm。在最优工艺参数下，制件的最大减薄率为14.35%，最大增厚率为8.38%，模拟结果的成形质量良好，并进行实际的冲压成形实验，实际制件与有限元模拟结果相比，最大减薄率误差为7.65%，最大增厚率误差为0.6%。制件无破裂、起皱，表面质量良好，模拟结果与实验结果基本吻合。

For the defects existing in the actually stamping of rear axle housing in automobile, the stamping process of rear axle housing was numerically simulated by software DYNAFORM, and the influences of blank holder force and stamping speed on stamping were analyzed. Then, taking the maximum thinning rate as the evaluation index, selecting stamping speed, blank holder force, friction coefficient and clearance between punch and die as the factors, the orthogonal experiment was designed to optimize the process parameters. The results show that the primary and the secondary relationship of influences for the various factors on the maximum thinning rate is stamping speed, friction coefficient, blank holder force and clearance between punch and die successively. The optimal forming process parameters are the stamping speed of 1000 mm·s-1, the blank holder force of 300 kN, the friction coefficient of 0.12 and the clearance between punch and die of 6.2 mm. Under the optimal process parameters, the maximum thinning rate of part is 14.35%, the maximum thickening rate is 8.38%, and the forming quality of simulation results is good. Finally, the actual stamping experiment was carried out. Compared with the finite element simulation results and the actual part, the error of the maximum thinning rate is 7.65%, and the error of the maximum thickening rate is 0.6%. Furthermore, the surface quality of parts is good without crack and wrinkle, and the simulation results are basically consistent with the experimental results.

基金项目：

江西省重点研发计划（20192BBEL50013, 20181BBE50011）

胡义华（1972-），男，硕士，高级工程师 E-mail：hyh@jlchassis.com 通讯作者：黄志超（1971-），男，博士，教授 E-mail：hzcosu@163.com

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