锻压技术

电动汽车座椅横梁辊冲成形仿真与试验研究

英文标题：Simulation and experiment research on chain-die forming of EV seat beam

单位：1.上海交通大学机械系统与振动国家重点实验室 2.昆士兰大学机械与矿业工程学院 3.宝山钢铁股份有限公司研究院 4.汽车用钢开发与应用技术国家重点实验室(宝钢) 5.上海交通大学船舶海洋与建筑工程学院

分类号：TG335

出版年,卷(期):页码：2022,47(9):51-57

摘要：

为了解决采用传统薄板成形工艺制造超高强钢座椅横梁成形缺陷多、尺寸精度低的问题，提出了两道次辊冲成形工艺方案，并基于Abaqus/Standard建立了相应的有限元模型，分析了辊冲成形过程中零件上的应变分布、成形载荷和截面形状。仿真结果表明，辊冲成形后的零件上无起皱与开裂缺陷，零件的横、纵截面尺寸与目标较为一致。基于现有的辊冲成形机组，开展了电动汽车座椅横梁两道次辊冲成形试验，并测量了成形零件的关键尺寸，其中法兰外轮廓的尺寸偏差小于±0.5 mm，满足焊接装车要求。该研究表明，辊冲成形工艺可以在室温下成形超高强钢车身变截面梁类零件，有助于推动其在超高强钢市场的应用。

In order to solve the problems of many forming defects and low dimensional accuracy for the seat beam of ultra-high strength steel by traditional thin sheet forming process, a two-pass chain-die forming process scheme was proposed, and the corresponding finite element model was established by Abaqus/Standard. Then, the strain distribution, forming load and section shape of part during the chain-die forming process were analyzed. The simulation results show that there are no wrinkles and cracks on the part after chain-die forming, and the dimensions of the transverse and longitudinal sections for the part are relatively consistent with the target. Based on the exiting chain-die forming unit, the two-pass chain-die forming experiment of EV seat beam was carried out, and the key dimensions of formed parts were measured. The dimensional deviation of flange outer contour is less than ±0.5 mm, which meets the requirement of welding. The research results show that the chain-die forming process can form variable-section beam parts of ultra-high strength steel body at room temperature, which is helpful to promote its application in the ultra-high strength steel market.

基金项目：

国家自然科学基金资助项目（U1860110）

刘洋（1997-），男，博士研究生 E-mail：liuyang0312@sjtu.edu.cn 通信作者：李大永（1973-），男，博士，教授 E-mail：dyli@sjtu.edu.cn

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