彈簧座論文：彈簧座沖壓成形數(shù)值模擬及工藝優(yōu)化

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1、彈簧座論文：彈簧座沖壓成形數(shù)值模擬及工藝優(yōu)化【中文摘要】彈簧座由于其螺旋面帶來的非對稱性,使其沖壓成形過程中的受力變形狀態(tài)要比一般的對稱件復(fù)雜得多。按照工廠原有工藝流程進(jìn)行生產(chǎn)時,其拉深工件在凸臺側(cè)壁等質(zhì)量關(guān)鍵部位厚度分布極不均勻,增厚、變薄都相當(dāng)嚴(yán)重而達(dá)不到產(chǎn)品質(zhì)量要求；翻邊工件局部有破裂的趨勢；翻孔工件極易在U形缺口處產(chǎn)生裂紋,產(chǎn)品質(zhì)量難以控制。為克服彈簧座的成形缺陷及探明成形特點(diǎn),本文利用數(shù)值模擬技術(shù),建立了零件拉深、翻邊等整個成形過程數(shù)值模型,以特征點(diǎn)的形式呈現(xiàn)出了拉深工件質(zhì)量關(guān)鍵部位的變形特點(diǎn),并通過多工步模擬反應(yīng)出了厚度、應(yīng)變狀態(tài)等信息在工序間的傳遞情況。工序間的應(yīng)變及厚

2、度變化信息表明,后一工序基本上不影響前一工序所確定的成形質(zhì)量,可以通過調(diào)整單一工序逐個改善各缺陷部位的質(zhì)量來提高總體質(zhì)量。針對拉深工件的質(zhì)量問題,在模擬試驗(yàn)基礎(chǔ)上以凸臺部位的凸模圓角半徑和模具間隙為影響因素建立了拉深工件質(zhì)量關(guān)鍵部位材料的最大減薄率和最大增厚率的回歸分析模型。根據(jù)兩回歸分析模型對工件質(zhì)量進(jìn)行了多目標(biāo)優(yōu)化,得出了質(zhì)量評價模型,擬出了可生產(chǎn)出合格工件的最佳工藝參數(shù)。針對翻邊工件質(zhì)量狀況進(jìn)行了工藝參數(shù)可行性分析,分別得出了對模具間隙、凹模圓角半徑或凸模圓角半徑進(jìn)行單一調(diào)整即可達(dá)到工件質(zhì)量要求的工藝參數(shù)。針對翻孔過程中U形缺口邊緣出現(xiàn)的破裂現(xiàn)象,在數(shù)值模擬的基礎(chǔ)上運(yùn)用正交試驗(yàn)

3、對合理工藝參數(shù)展開了尋找。由試驗(yàn)結(jié)果表明,限于零件缺口的位置要求,很難以調(diào)整工藝參數(shù)的方式來完全克服產(chǎn)品的破裂缺陷,需要調(diào)整工序內(nèi)容來改善零件的成形質(zhì)量。通過調(diào)整沖孔、翻孔等工序內(nèi)容后,產(chǎn)品的質(zhì)量得到了保證?！居⑽恼緽ecauseofitsspiralsurfacewhichcausesasymmetry,thedeformationstateofspringseatinthestampingprocessismuchmorecomplicatedthanthatofgeneralsymmetrypart.Accordancewiththeoriginalproductionpr

4、ocess,asthethicknessdistributionofdrawingworkpieceisextremelyuneveninkeypositions,boss,thickeningandthinningaretooserioustomeetthequalityrequirementsofproduct;workpieceofflanginghasriskofcrack;intheholeflangingoperation,cracksextremelyeasilyoccurontheedgeofU-notch,whichmakethequalityofproductto

5、odifficulttocontrol.Inordertoovercomethedefectsandascertaintheformingcharacteristicsofthespringseat,usingnumericalsimulationtechnology,thispaperestablishesallofthenumericalsimulationmodelsoftheformingprocesswhichincludedrawing,flanging,andholeflanging.Thedeformationcharacteristicsofdrawingworkp

6、ieceinthekeypositionsarepresentedbyseveralfeaturepoints.Throughthemulti-stepsimulationinthispaper,thetransferaboutthickness,strainandotherinformationarewellreflected.Theinformationofthicknessandstrainindiferentoperationsshowthattheformingqualitywhichevaluationedbythepreviousoperationdoesnotsuff

7、ertheinfluenceofthenextone.Therefore,theoverallqualityofspringseatcanbeimprovedinthemannerofimprovingthequalityofdefectivepositionstepbystep,bycarryingoutsingleoperation.Inviewofthedrawinigworkpiece’sformingqualityproblem,tworegre