【摘要】：隨著環(huán)境污染加劇、能源緊張和汽車配置的增多,汽車輕量化成為研究熱點(diǎn)。輕質(zhì)材料鋁合金取代鋼材在車身上大面積使用,可以大大的減輕汽車重量。鋁合金板沖壓成形性能比普通鋼板差,尤其應(yīng)用于大型的汽車覆蓋件沖壓成形過(guò)程中,更易出現(xiàn)破裂、起皺、回彈和表面損傷等質(zhì)量缺陷,所以鋁合金板沖壓成形工藝的設(shè)計(jì)不能簡(jiǎn)單地套用普通鋼板的經(jīng)驗(yàn)和標(biāo)準(zhǔn)。同時(shí),相比于國(guó)外鋁合金在車身上的廣泛應(yīng)用,國(guó)內(nèi)在這方面正處于研究和嘗試階段,所以需要對(duì)鋁合金覆蓋件的沖壓成形工藝進(jìn)行深入研究。本文將以某款汽車的鋁合金后背門(mén)外板為研究對(duì)象,運(yùn)用有限元數(shù)值模擬和數(shù)學(xué)優(yōu)化等手段,探究如何高效準(zhǔn)確地對(duì)鋁合金板進(jìn)行合理的成形工藝設(shè)計(jì)、成形質(zhì)量?jī)?yōu)化及影響因素分析,回彈控制。研究成果和方法對(duì)于研究和制定其他鋁合金件成形工藝具有一定的指導(dǎo)意義。本文的主要研究?jī)?nèi)容有以下幾個(gè)方面:(1)分析零件的結(jié)構(gòu)和成形特點(diǎn),并根據(jù)鋁合金板成形性能,安排合理的沖壓工序;然后借助UG造型設(shè)計(jì)和Autofrom有限元數(shù)值模擬技術(shù)相結(jié)合的方法,制定出合理的成形工藝模面,包括拉延方向、工藝補(bǔ)充面、壓料面;然后,選取三種拉延筋布置方案進(jìn)行成形過(guò)程數(shù)值模擬,結(jié)果表明非封閉式雙筋方案可以較好的控制板料均勻流動(dòng),成形質(zhì)量較好;比較三種鋁合金材料AA6009-T4、AA6016-T4和AA6111-T4在此零件成形時(shí)成形性差異,結(jié)果顯示:AA6016-T4板塑性變形較充分、但易局部破裂,AA6111-T4成形性相對(duì)差,但不要破裂,AA6009-T4板成形性居中。(2)針對(duì)零件成形過(guò)程容易產(chǎn)生破裂和起皺缺陷,選取壓邊力、摩擦系數(shù)、模具間隙和凹模圓角半徑這四個(gè)工藝參數(shù)作為優(yōu)化變量,以最大減薄率和最大增厚率為優(yōu)化目標(biāo),利用Box-Beheken試驗(yàn)和二階響應(yīng)面法建立了優(yōu)化變量與目標(biāo)之間的非線性映射關(guān)系,并預(yù)測(cè)了單因素及多因素交互作用對(duì)優(yōu)化目標(biāo)影響規(guī)律。然后,用NSGA-II遺傳優(yōu)化算法進(jìn)行多目標(biāo)尋優(yōu),找到了有效控制破裂和起皺的工藝參數(shù)組合。(3)鋁合金彈性模量易回彈,同時(shí),零件卸載和修邊后的回彈計(jì)算結(jié)果顯示其回彈大且分布不均勻。所以采取模面修正補(bǔ)償技術(shù)對(duì)成形工藝模面進(jìn)行了四次迭代補(bǔ)償,將修邊后回彈控制在公差允許范圍±0.50mm內(nèi)。
[Abstract]:As environmental pollution intensifies, energy stress and vehicle configuration increase, vehicle lightweight has become a research hotspot. Light-weight aluminum alloy to replace steel in the body of large-area use, can greatly reduce the weight of cars. The forming performance of aluminum alloy sheet is worse than that of common steel plate, especially in the process of stamping forming of large automobile panels, it is more likely to appear quality defects such as rupture, wrinkle, springback and surface damage, etc. Therefore, the design of aluminum alloy sheet stamping process can not simply apply the experience and standard of common steel plate. At the same time, compared with the extensive application of aluminum alloy in the body of foreign countries, this aspect is in the research and try stage in our country, so it is necessary to deeply study the stamping forming process of aluminum alloy panel. In this paper, the aluminum alloy back door plate of a certain automobile is taken as the research object, the finite element numerical simulation and mathematical optimization are used to explore how to carry out the reasonable forming process design of the aluminum alloy plate efficiently and accurately. Forming quality optimization and influencing factors analysis, springback control. The research results and methods have a certain guiding significance for the study and development of other aluminum alloy forming process. The main research contents of this paper are as follows: (1) analyzing the structure and forming characteristics of the parts and arranging the reasonable stamping procedure according to the forming properties of the aluminum alloy sheet; Then with the help of UG modeling design and Autofrom finite element numerical simulation technology, the reasonable forming process die surface, including drawing direction, process supplement surface, compaction surface, is worked out. Three kinds of drawing bars are selected to simulate the forming process. The results show that the non-closed double reinforcement scheme can better control the uniform flow of sheet metal and the forming quality is better. The formability differences of three aluminum alloy materials AA6009-T4, AA6016-T4 and AA6111-T4 in forming process were compared. The results showed that the plastic deformation of 10% AA6016-T4 sheet was sufficient, but the formability of AA6111-T4 was relatively poor. However, the formability of AA6009-T4 plate should not be ruptured in the middle. (2) in view of the fracture and wrinkling defects in the forming process of the parts, four technological parameters, namely, the blank holder force, the friction coefficient, the die clearance and the corner radius of the die, are selected as the optimization variables. With the maximum thinning rate and the maximum thickening rate as the optimization targets, the nonlinear mapping relationship between the optimization variables and the target is established by using the Box-Beheken test and the second-order response surface method, and the law of the influence of single factor and multi-factor interaction on the optimization target is predicted. Then, the NSGA-II genetic optimization algorithm is used for multi-objective optimization, and the combination of process parameters to effectively control the rupture and wrinkle is found. (3) the elastic modulus of aluminum alloy is easy to rebound, and at the same time, The results of springback calculation after unloading and trimming show that the springback is large and the distribution is uneven. So the die surface compensation technology is used to compensate the die surface for four times, and the springback after trimming is controlled within the allowable range of tolerance 鹵0.50mm.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：U466;TG386

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本文編號(hào)：2180014