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以某车身铝合金内板件为研究对象,利用有限元模拟软件ABAQUS建立了翻边及回弹过程的有限元模型。通过优化上弯曲半径R1、下弯曲半径R2、翻边角度α等3个产品特征参数和润滑条件μ、模具间隙T等两个工艺参数,来减小回弹值和降低弯裂风险。结合正交试验和灰色关联的方法将多目标问题转化为单目标问题,得到较优的设计参数指导产品设计,并进行试验验证。结果表明,影响综合目标的主次顺序为:模具间隙>翻边角度>上弯曲半径>下弯曲半径>摩擦系数,得到优化后的组合参数为R1=5 mm,R2=9 mm,a=75°,μ=0.1,T=t,采用优化后的参数设计零件,得到的实际零件的回弹在公差范围内且无弯裂缺陷。
Taking the aluminum alloy inner panel of a car body as the research object, the finite element model of the turning and rebound process was established by the finite element simulation software ABAQUS. By optimizing the three process parameters, the upper bending radius R1, the lower bending radius R2, the flanging angle α, and the two lubrication parameters μ and the mold clearance T, the rebound value and the risk of cracking are reduced. Combined with orthogonal test and gray relational method, the multi-objective problem is transformed into a single-objective problem, and the design parameters are given to guide the design of the product, and the experimental verification is carried out. The results show that the order of the primary and secondary factors influencing the comprehensive objective is as follows: die clearance> flange angle> upper bending radius> lower bending radius> friction coefficient. The optimized combination parameters are R1 = 5 mm, R2 = 9 mm, a = 75 °, μ = 0.1, T = t. The optimized part is used to design the part. The resulting spring back of the actual part is within the tolerance range and there are no bending defects.