锻压技术

超高强钢辊压成形门槛梁轻量化设计

英文标题：Lightweight design on side sill beam of ultra-high strength steel by roll forming

作者：吴海波1 侯迪2

分类号：TG142.41；TG332+.4

出版年,卷(期):页码：2025,50(7):88-95

摘要：

针对HC550/DP980D+Z超高强钢门槛梁开展轻量化设计，考虑弹性和塑性阶段吸能差异，对高强钢等效减薄公式进行修正，并根据HC820/DP1180D+Z超高强钢的性能，获取减薄后材料的厚度。对材料优化后的成形工艺进行设计，检测分析生产零件的型面公差和减薄率，并基于静态三点弯曲和动态落锤冲击，对比了门槛梁的承载和吸能特性，以验证设计的轻量化方案的可行性。结果表明：采用HC820/DP1180D+Z超高强钢生产门槛梁厚度减薄至1.3 mm，轻量化减重约15.38%；辊压成形需要26道次，强度和最大应变均满足生产要求；零件实测型面公差全部点位均合格，最大减薄率为11.43%；静态三点弯曲峰值载荷为14.2 kN，动态落锤冲击峰值载荷为16.0 kN，平均载荷为7.2 kN，均优于原设计方案。采用修正等效减薄公式开展轻量化设计是可行的。

The lightweight design of sild sill beam for HC550/DP980D+Z ultra-high strength steel was carried out, and considering the energy absorption difference between elastic and plastic stages, the equivalent thinning formula of high strength steel was modified. Then, according to the properties of HC820/DP1180D+Z ultra-high strength steel, the thickness of material after thinning was obtained, and the optimized forming process of material was designed. Furthermore, the profile tolerance and thinning rate of the produced parts were tested and analyzed, and based on static three-point bending and dynamic drop-weight impact, the load-bearing and energy absorption characteristics of sild sill beam were compared to verify the feasibility of the lightweight scheme. The results show that the thickness of the sild sill beam produced with HC820/DP1180D+Z ultra-high strength steel is reduced to 1.3 mm, which reduces the weight by about 15.38%. Twenty-six passes are required for roll forming, and both the strength and the maximum strain meet the production requirements. The measured profile tolerances of all points for the part are qualified, and the maximum thinning rate is 11.43%. The peak load of the static three-point bending is 14.2 kN, the peak load of the dynamic drop-weight impact is 16.0 kN, and the average load is 7.2 kN, which are all better than the original design scheme. Thus, it is feasible to use the modified equivalent thinning formula to carry out the lightweight design.

基金项目：

安徽省高等学校科学研究重点项目（2023AH052789）；湖南省教育厅科学研究课题（23C0540）

作者简介：吴海波（1989-），男，硕士，讲师 E-mail：wuhaibo@mastc.edu.cn

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