锻压技术

电机端盖HC260高强钢冲压工艺优化

英文标题：Stamping process optimization of HC260 high-strength steel for motor cover

作者：张勋1 2 李国林2 柳玉起1 林滔2 张镇2

单位：（1.华中科技大学材料科学与工程学院湖北武汉 430074 2. 美的集团智能制造研究院广东佛山 528311)

分类号：TG386

出版年,卷(期):页码：2023,48(6):22-28

摘要：

为了将电机端盖用材料由厚度为1.0 mm的DC54热镀锌材替换为厚度为0.8 mm的HC260高强钢，提出了一种新的冲压工艺方案。首先，通过FASTAMP模拟和实验对常用的3工序成形工艺方案进行验证，结果显示，产品在中心反拉凸包位置发生严重破裂。其次，通过冲压成形理论分析了破裂原因并制定了新的冲压工艺方案，即在OP10拉深工序前增加OP05预拉深工序，并增大OP10拉深的工序的凸凹模间隙，使中心反拉区域断面线长增大，使其与产品型面的比值>0.9，确保在后续成形中反拉区域有足够的材料。再次采用FASTAMP冲压成形全工序数值模拟方法对新的4工序成形工艺方案进行验证，结果显示，新的4工序成形工艺方案解决了零件的破裂问题，最大减薄率为27%。最后，根据新的4工序成形工艺方案制作了新模具并进行了试模验证，现场1次试模成功，证明了FASTAMP软件全工序数值模拟的有效性与准确性。

For the motor end cover meterial, a new stamping process was proposed to replace DC54 hot-dip galvanized material of 1.0 mm with HC260 high-strength steel of 0.8 mm. Firstly, the existing 3-step forming process scheme was verified by FASTAMP numerical simulation and experiment, and the result shows that the product is serious cracked at the center of reverse pull convex hull. Secondly, the reason for rupture was analyzed through the stamping forming theory, and the new stamping process plan was formulated, that is, the OP05 pre-drawing process was added before the existing OP10 drawing process. Furthermore, the gap between punch and die of OP10 drawing process was increased to increase the section line length at the central reverse drawing area, which leaded to the ratio between it and product profile over 0.9, so as to ensure that there was enough material at the reverse drawing area to deform in the subsequent forming. Thirdly,the new 4-step forming process scheme was verified by using FASTAMP numerical simulation method for the whole process of stamping. The results show that the new 4-step forming process scheme solves the cracking problem of parts, and the maximum thinning rate is 27%. Finally, according to the new 4-step forming process scheme, a new die was made and tested for verification. The results show that the die is successfully tested once on site, which proves the validity and accuracy of the numerical simulation for the whole process by software FASTAMP.

基金项目：

广东省重点领域研发计划项目（2021B0101220001）

张勋（1991-），男，博士研究生

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