汽车后地板多步拉延工艺数值模拟

汽车后地板多步拉延工艺数值模拟 2006??11?F???-?9???????(37???(11?r ?????A?x???-?????????????]?P?? 3 , ?-?????R???????i?????S??FLD????x2?????????7?6???????? ?????????7??,?a?????????A?x???-???????i?????????i???T?????K????,?????c?-???5???????????????????? ?i??????x0 ???)??:????x???????x??-??????x????]?P?? ?y???7????:U466???)?,???2:A SimulationofMulti-stepSheetMetalFormingProcess forAutomotiveRearFloor YuanGuodingx?YangTingx?JiangYinfangx?ChenWei (JiangsuUniversity) Abstract Thenumericalsimulationandactualpressexperimentwerecarriedouttoanal yzetheFLD curve,thethicknessdistributionchartandthestrainpathchartofthetwo2step2 drawingforming, andthemulti2steppressformingcharacteristicoftheautomotiverearfloorandthecontrol methodoftheformingqualitywerestudiedemphatically,soastodesignthedeformingprocess withchangingstrainpathandofferbasisforthedesignandmanufactureofthemould. Keywordsx?Vehicle,Panel,Multi2stepforming,Numericalsimulation ?K?H???r:2005-09-09 3(?????o??5KD6)???y???????A?????????=??????(?????o???y????[]??) ??????x??????d???9?????:????x?????,3x??I???0 ??x??7x??????d???9?????:????x??????r ??????x??????d???9?????:????x????? ??x???x??????d???9?????:????x????? x?x??t?? ???????????A???(??????????,???L???????? ?????Sx2?????4?Ex2?????9???dx2?i???T?????E???? ????,?????????i?????????L????x2????x2????x2?b?? ???-?????S,?????T?i?????:?y?1???7?????????2 ?-?9?4?E,???W???d,?1?1?????????4?I??,????,?T ?????????i?????????????P????????,?????6???1 ???7???????????I???dx0?????????????D???d???? ?9???????????????4???????????????????:??,?? ????????????;???????????????S???9???????4?? ?r?5?d????,?i???A?????L???r???-??;?U???????z ???????i?????:?y?????????????5x2????x2???????R ???i??????x0 ?????????A?x???9?a??????,???????i?????] ?P???9?[???a??????,?7???-????????????????,?? ?U?9?P?????????K?g????????x0 1x??A?x???????????7?? ??1x??A?x???????7???? Fig.1x?Rearfloor structureanalysis ?A?x???b?????????? ??(??1),?????????4?E, ?w???b??????????,?9?? ?S?P???????A???????? ?5,???????T???d?????? ??????????????;????A ????????,?????L?9???? ?????-???U?????????9?? B,?????????????????O?????[??,?T???9???????d :0J40044:200114 21201 ; ????C?????Z?????9,?????S?z?????????????-?? ?4??x0 ?5?????D?7??,?U???6???x?T?????????i???T ?????????:,???;?????m????????????,?(???????? 2?C????x0????1???T?????????i?????????8?????? ??x0????2???T?R???????i??,?????i???????????? A?9????????,?Z????????C?9?????4?i??,?5???? ?9??B?9??????,???S?i?????????O?????[??,?K?A ???i????C?9??B?9??????x0 ?9???????i??????,?7?A?x???????????????? ?????F?????9?????????F,???U??????????????,?L ?J???z?????r?????q??x2?????????????i???9??x0 2x????????]?P?????????7?? 211x????r?P?????L?????? ?5???A?x????CAD?P?????????P??(?3???? ?Px2???Px2?????F)??CAD?P??,?K?A???T???]?u?7 ????Hypermesh???????]?u?7,?????L???%???]?P ??(????2a)x0 ?J?TDynaform???????r?P??,?P???9?-?d??, ???????%???TBT?????%,?????1?7???T?????,?? ?????????????????P??,???????9?r????????(?? ??2b,2c)x0?9????n?d???],??x2???P?7??r??5mm,?? ??????????:R?????1?p???x???P?????????????] ?6??1500??2000kNx0R?????2?(1???????P?? ??2x??L???%???]?P??x2?r?????????P?????6?????S Fig.2x?Finiteelementmodel,modelofrealdrawbeadandlayout (a)?????L???%???]?P??x?(b)?r?????????P??x?(c)???????6?????S 1.???Px?2.?????Fx?3.????x?4.???P x? ??????????1500??2000kN;?(2???????P?????? ??????400??800kNx0???????TST14O5??????,?? ???9018mm,???4?9??Ρs?9160??170MPa,?????9 ??Ρb?9300??320MPa,?????9?o?,??n?90118?? 0123,?????9?o????k?9570??620,???m?0?d?,??r00 ?9118??212,r45?9115??118,r90?9118??212x0 ??3x?????1???????????r????x2?i?????????? ???9??E-E?????????9?S?? Fig.3x?FLDchartofscheme1drawingformingand f2 ()???????????????r???????i????????x?()?(???????? ?9???C??(????)x?()?(?????????9???C??(?? ??) 212x????r???? ?-?????]?P??????????1?4????(????3a),?8 ?????T?R??????,?????-?P?P??,?????R?????????? ???????d?S:?(1???91500kN,?(2???9400kNx0?( 1???????T???d???????????T?:?????i?????????? ????????,?U???7???9???????????5??(????3),?( 2???????[???b?i????C?9????B?9???9???????? ??x0??4?b????2???????r???????i????????x0 ?P???????B?9?(1????????????,?????TC?9 ??????????(????4a),???[???b?w?R???????O???? ?l?:???4?U?g?i??x0???????????????????????l?O ??,?????????M?????O??,?g?i?????T???????????r ?7??,?8??????????????????x0?6???x?T?????????9 ?????????????P????,???a?A?x???b????????,???? ???o???T?????E?4??,?O???T?(1?????????????? ??x0??4b?b?(2?????????r???????i????????,?P?? ?????????A?(1?????????r???????T?(2???????? ?????????(????x0 ??4x?????2???????r???????i???????? Fig.4x?FLDchartofscheme2drawingforming (a)?(1??????x?(b)?(2?????? x? 213x??A?x?????i???T???7?? ?i?????????????D???7?94?C?9??:???m???? gaga?????????9x2????????gaga???m?????9x2???m?? ??gaga?????,?9x2?????,gaga???m???J?9,???????T ?????C?9???7?W???r????????x2?????i??x2?????i?? ???????i??x0 831??x??-x??9x???x???x???2006??x? strengtheningribocrosssectionE-E a1b1 E-Ec2E-E 4?????:?x,?(1????????????,?A?x???Z ?????9?d???7?1?T???m???J?9??,?????9?????r?? ????x0?(2????????????,???9?1?T???m???J?9???? ?????d?d???m,?w?????T?Z????,???????(????x0 ?-??????1?y??????B????????????(??5a), ?????:???????????(?1?????????????2,?w???[?? ?????d?U???????i??????????;???T????2?A???? ?????????1???????????9(??5b),?[???????d,?P ???????S,???????:?L???x?z???????????s?????S ???????5??x0????3?y??????A????????????5c,?? ?AA???????T???P?9????,???C?????q???9x0 ??5x???????x2???????????????? Fig.5x?StrainpathofdangerouspointBandobservingpointA (a)????1??????B??????????x?(b)????2??????B??????????x?(c)????3?? ????A?????????? x? 3x????r?????A???????????? ?9???6???P????????,?7???r?????A???????? ??????????x0?L???(2?????????i?A??????,?7???r ???x???????A??????????????????x0 ???T???????,???7???????8???????,???i3?? (??6),?K?A?T???K???????%?7?9?????????D???)?? ??????????,???T?P???????y?L???????????????? ????,?????????????A?P??????????????x0??7?b?? ?r?????A????????????????,?????y?????:??,?? x?x? ??6x??????????9?S???? ?,???A???????????? Fig.6Measurementcurve andphotoofcutpart x? ?r???????????????[?F?? ????,?4?????8?1???6?? ?D?R?3?????o???????(?? ??,?U?a?d???7?9???[?F ?????x80%????,?????A ???r?????b??????x0??8 ?b?R?????????Z???????? ?????????I,???(1???? ?????????????:?x,???Z?????y???????P???y???? ??????????,???????????A???P?????????dx0 ??7x????r?A???????????????? Fig.7x?Contrastbetweensimulationandactualmeasurementcurves (a)OA??x?(b)OB??x?(c)OC?? x? ??8x?????2?????????????? Fig.8x?Drawingpartofscheme2 (a)?(1??????????????x?(b)?(2?????????????? x? x????? ()?1?????????S?D?b??????,?(?T?D???????? ?????d?????9???G?????T????,?????????y?????d ?????-???A????????????,???U?????A????????x0?8 ???T?(1???????????y,?w???????O???????l?:?? ?4?U?U?g?i??????,?T?(2???????????y???x????x0 (2)?????????y?????????(?1?????????????2, ?w???[???????d???U???????i??????????,?-???? ???6???????????????1???????????9,?[???????d, ?P???????S,???K?T?i??????????????x0 (3)?1???y?????d????????????,???????????? ????????x0?P???A?????????A,?-???6???????????5 ??????????,?J?T?4?U?????:?i?????????4?U,???? (?:???(??) 931x??(11?r????????:?????A?x???-?????????????]?P?? 4 1 142 40520Nx2???????????90118mm??,?????7???? ?????????r???????????A?7???????????????????? ????????,Ρxr=15717MPa,Ρyr=43110MPa,Ρzr= 26218MPax0?????????A???Q???:?7???x?D?7???? ????????????????????2?8?9x0 ??2x??????????A???Q???????????????7?6???? Fig.2x?Residualstressesdistributioncurvesunder filletaftersurfacerolling x? ?7?L???%?P?????x???????????]?????S(2),?5 ???????????????7??,?????T?????????????2?:???? ???????????????Sx0???????d??????????????????x0 ?9?????????????????????????????????????F ????,?7???????????????????E?? [5] x0??3?B?9???b ???F?6???7?????????????????A?????7???????x?? ????????????????????x0?????y?????:???7?????? ?=???????????2?9?????????2x0?5?????D?L???%?7 ??,?????????????????????940520N(?????????? 118mm)x0 ??3x??6?????????????????????????????? Fig.3x?Stresscurvesconsideringtheresidual stressunderfilletatworking x? 4x????? (1)??????YC4110ZQ?????????????:?????f ???????940520N(??????????0118mm)x0 (2)?J?T?????????I???????????x?????4?U?? ???:?????????????,???????????????7?6x0 ???6???) 1x??f????.???????????:??[M].?n??:???????-?????B,1995:178??199. 2x?PopinocanuNG,DiaconcscuE,CretuS,etal.Criticalstressesinrollingco ntactfatigue[J].Wear,1981,71(3);265 ??268. 3x??,?v,???d?D.?????9????[M].?J?Y:?J?Y?d???????B,1989:138??141. 4x??5?m??.?????9?????????f?o????????[J].?????9???:,1998(3):26??29. 5x?ChienWY,PanJ,CloseD,etal.Fatigueanalysisofcrankshaftsectionsunderbendingwithconsiderationof residualstresses[J].InternationalJournalofFatigue,2005,27(1):1??19. (?D???(139??) ???????A?????????????????T?????6????,???Z?7 ???Y???????i???d??,???????????i???T??x0?????? ?T???]?P???????5??????????,?????i??????,???9 ?P?????????K?g????????x0 ???6???) 1x?????.???????]?P???????????????-???????????a??[D].?I??:?????d??,2002. 2x??g????,???R??,??????,??.???????????-???????i?????]?P?????b?a??[J].???d???:????,2001,8(1):25??30. 3x???????,????,???9?m,??.???????-???????y???????????i???d????????[J].?????b??????,2005(5):53??55. 4x?EscheSvenK,KhamitkarSudheer,KinzellGaryL,etal.Processanddiedesignformulti2stepformingofround partsfromsheetmetal[J].JournalofMaterialsProcessingTechnology,1996,59(1??2):24??33. 5x?SitaramanS,KimazelCL,AltanT.Processsequencedesignformulti2stageformingofaxisymmetricsheetmetal Rff[R]OSUy,8 241??x??-x??9x???x???x???2006??x? parts:ECornetshapemanuacturing.Columbus:hiotateniversit199.