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Abstract：
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The manufacturing process difficulties of thermoforming door ring were studied, and based on the conventional thermoforming scheme, the integration and optimization were conducted to solve the forming wrinkling problem of door ring by using three pressing blocks. Then, the product was optimized by combining with the forming results of CAE analysis, and the rationality and feasibility of the scheme were verified by actual production. Furthermore, the deformation, cracking and deviation of welding line were mainly optimized. The analysis shows that the large flow amount of materials at the corner leads to the deformation of welding line and then cracks, so the welding line should be set in the straight section with small flow amount of material. At the same time, the CAE analysis curve of welding line is reversely output for product matching to achieve the consistency of design and manufacture, and the welding line deviation is controlled within ±3 mm in production validation. In addition, the springback mechanism and precision control method of thermoforming were further studied, and the main causes of deformation for parts are the change of stress-strain fields and thermal expansion and cold contraction caused by metallographic transformation during the cooling process of thermoforming. The CAE analysis shows that reducing the die clearance can reduce the springback of parts. In the processing data, the zoom factor 0.172% is used to compensate the thermal expansion and cold contraction of parts. After the die clearance is reduced, the springback compensation is adjusted, and the accuracy measurement is conducted with the pass rate of 95%.
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Funds：
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国家04科技重大专项基金项目（2018ZX04023001-04）
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AuthorIntro：
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作者简介：杨建（1981-），男，学士，工程师，E-mail：yangjian@gacrnd.com；通信作者：覃显峰（1985-），男，学士，E-mail：qinxianfeng@gacrnd.com
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Reference：
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