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摘要：
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针对热成形门环的制造工艺难点进行研究，在常规热成形方案的基础上进行整合优化，采用3个压料块结构解决了门环的成形起皱问题，并结合CAE分析结果对产品进行优化，最终通过实际生产验证了该方案合理可行。重点对焊缝的变形、开裂及偏差进行优化，分析表明：拐角位置材料流动量大，导致焊缝变形进而开裂，焊缝应当设置在材料流动量小的直线段；同时，将焊缝的CAE分析曲线反向输出进行产品匹配，实现设计与制造的一致性，生产验证中焊缝偏差控制在±3 mm范围内。进一步研究热成形的回弹机理及精度控制方法，热成形冷却过程中金相转化产生的应力、应变场改变以及热胀冷缩是零件变形的主要原因，CAE分析证明，减小模具间隙可以减少零件回弹变形。在加工数据上采用缩放因子0.172%对零件的热胀冷缩进行补偿，通过研合模具减小间隙后调整回弹补偿量，最终进行精度测量，合格率达到95%。
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The manufacturing process difficulties of thermoforming door ring were studied, and based on the conventional thermoforming scheme, the integration and optimization were conducted to solve the forming wrinkling problem of door ring by using three pressing blocks. Then, the product was optimized by combining with the forming results of CAE analysis, and the rationality and feasibility of the scheme were verified by actual production. Furthermore, the deformation, cracking and deviation of welding line were mainly optimized. The analysis shows that the large flow amount of materials at the corner leads to the deformation of welding line and then cracks, so the welding line should be set in the straight section with small flow amount of material. At the same time, the CAE analysis curve of welding line is reversely output for product matching to achieve the consistency of design and manufacture, and the welding line deviation is controlled within ±3 mm in production validation. In addition, the springback mechanism and precision control method of thermoforming were further studied, and the main causes of deformation for parts are the change of stress-strain fields and thermal expansion and cold contraction caused by metallographic transformation during the cooling process of thermoforming. The CAE analysis shows that reducing the die clearance can reduce the springback of parts. In the processing data, the zoom factor 0.172% is used to compensate the thermal expansion and cold contraction of parts. After the die clearance is reduced, the springback compensation is adjusted, and the accuracy measurement is conducted with the pass rate of 95%.
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基金项目：
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国家04科技重大专项基金项目（2018ZX04023001-04）
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作者简介：
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作者简介：杨建（1981-），男，学士，工程师，E-mail：yangjian@gacrnd.com；通信作者：覃显峰（1985-），男，学士，E-mail：qinxianfeng@gacrnd.com
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