锻压技术

轿车翼子板成形工艺分析与模具设计

英文标题：Forming process analysis and die design on automobile fender

作者：万志远

分类号：TG386

出版年,卷(期):页码：2023,48(8):202-209

摘要：

翼子板是轿车重要的外覆盖件之一，具有结构复杂、外形尺寸大、成形不易控制、表面质量要求高、材料厚度小、易产生回弹缺陷等特点。首先，分别选取翼子板零件工艺补充前后相同位置的15个典型截面进行结构分析，得到了零件典型位置的截面曲线变化情况，分析了与机舱总成、发动机盖总成、前门总成、侧围总成、前轮罩等重要位置搭接处的工艺补充面，为后续全工序设计奠定了基础。其次，根据结构分析，利用AutoForm等软件对轿车翼子板进行了工艺补充设计，确定了落料、拉延、修边-冲孔-侧修边、翻边-整形-侧翻边、侧翻边-侧冲孔-冲孔和侧翻边-侧成形6道全工序工艺过程。采用有限元模拟手段，对工艺补充后的零件进行了模拟计算，结果表明，翼子板零件的成形质量好，主体部位未出现开裂和起皱缺陷，材料的最大减薄率为24.3%，验证了工艺补充的合理性。最后根据工艺设计，重点设计了翼子板落料连续模具和拉延模具。

Fender is one of the important outer covers for a car, and it has the characteristics of complex structure, large size, difficulty in forming control, high surface quality requirement and small material thickness, which is easy to produce springback defects. Therefore, firstly, fifteen typical cross-sections at the same position before and after process supplement of fender part were selected for structural analysis, the change of cross-section curve for the typical positions of part was obtained, and the process supplementary surfaces at the important positions overlapping with engine room assembly, engine cover assembly, front door assembly, side panel assembly, front wheel cover etc. were analyzed, laying the foundation for the subsequent design of the whole process. Secondly, according to the structural analysis, the process supplement for automobile fender was designed by AutoForm and other softwares, and the whole process with six processes of blanking, drawing, trimming-punching-side trimming, flanging-shaping-side flanging, side flanging-side punching-punching and side flanging-side forming were determined. Furthermore, the finite element simulation method was used to simulate the parts after process supplement. The results show that the forming quality of fender part is good, there is no cracking or wrinkling defects in the main positions, and the maximum thinning rate of material is 24.3%, which verifies the rationality of the process supplement. Finally, according to the process design, the blanking continuous die and drawing die of fender are mainly designed.

基金项目：

山东华宇工学院校级协同创新中心 “智能装备技术研发协同创新中心”资助项目

作者简介：万志远（1988-），男，硕士，副教授，工程师 ,E-mail：815223128@qq.com

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