拉深工艺对制件质量和模具寿命影响的研究
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摘要
冲压加工作为一种高效、节能,高材料利用率的加工方法在现代工业制造中得到了广泛的应用。冲压技术水平的高低,已在相当程度上决定了企业的生产能力和在总体行业中的地位。因此,细化而深入研究冲压加工中的各类技术问题,已是现代冲压制造业共同的要求。
拉深加工是薄板料常见的冲压加工方法之一,板料通过模具作用,经塑性变形后,最后获得制品所需要的形状和尺寸。拉深过程中,板料产生塑性变形,材料被转移和重新分布,内部的应力和应变十分复杂,导致拉深过程中的状态难以精确控制。因此,通过控制坯料拉深时的局部应力应变状态来保证拉深件的质量,是取得拉深成功的关键。
本文通过对汽车灯具用类抛物面反射镜拉深工艺的设置及模具结构进行设计和优化,就拉深工艺对制件质量和模具寿命的影响进行对应研究。对雾灯反射镜拉深件的工艺和模具设计,在参照工艺可行性分析结果后,确定采用一道拉深制件主体至规定高度,在拉深后通过安排整形工序来定形制件外形和尺寸的工艺方案。本文所有实验全部依据实际生产进行,研究数据来自生产中的检测和统计。研究过程中对生产中的前大灯反射镜拉深件真实存在的各类质量问题进行分析,并通过改进工艺方案和优化模具结构设计,来解决拉深中制件的质量问题。
研究过程中,拉深工艺方案主要通过调整拉深中部分关键参数或组合、分解部分拉深工艺步骤,以及选择拉深设备等方法来实现,以达到拉深时坯料外部受力均衡的目的。通过修正拉深模工作部分的过渡圆角大小和分布等局部结构,优化坯料拉入凹模时的流动状况;对于前大灯反射镜初次拉深存在的各类问题,在模具对应制件料流不易控制之处,合理设置拉深筋来控制料流,最终解决制件拉深中出现的质量问题。
本文最后通过对不同拉深工艺方案下拉制的制件质量进行对比研究,结合生产中不同工艺方案和模具结构下模具的实际使用寿命,分析得出了拉深工艺对类抛物面拉深件拉深质量和模具寿命的影响关系。
Stamping process as a highly efficient, energy-saving, high material utilization method has a wide range of applications in the modern industrial manufacturing field. To a great extent, stamping technical level determines the capacity of such enterprises in the status in this field. Therefore, detailed and in-depth processing of stamping on the various problems have became common topics in modern manufacturing industry.
The drawing processing is one of the common ramming processing methods of thin sheet, through mold function, after plastic deformation, finally obtains the shape and size which the products need. In the drawing process, the sheet has the plastic deformation, the material is shifted and distributed, because of the complexity of the inside stress and strain, it is difficult to control the condition preciously in the drawing process. Therefore, through controlling the local stress strained condition to guarantee the drawing quality, which is key to obtain the drawing successful.
This article designs and optimizes the drawing process and the die structure of the automobile lamps and lanterns, makes a study of the corresponding research on the drawing craft to the workpiece quality and die life's influence. To fog lamp reflector drawing craft and mold design, considering the craft feasibility analysis result, determines drawing the main body of workpiece to the predetermined altitude, after the drawing comes the setting workpiece contour and the size craft plan through the arrangement reshaping working procedure. All the tests in this article based on the actual production, research data come from the productive examination and the statistics. make an analysis about drawing real existence each kind of quality question of the producing the head lamp reflector process, and through the improvement of craft plan and the optimized of die structural design, solves the quality problem in the drawing workpiece.
In the studies process, through adjust part key parameter of drawing and combining or separating the partial drawing craft step, as well as choosing drawing equipment, the drawing craft achieves the balanced goal when the drawing semifinished materials exterior stress. Through the revision drawing pattern making the excessive fillet size and the distribution as well as other partial structure, optimizes semifinished materials drag into when the lower die the mobile condition;
Before head lamp reflector primary drawing existence's each kind of question, place where the material class in the mold correspondence workpiece is not easy controlled, establishs drawbead to control the material flowing, which finally solves the quality problem in the workpiece drawing . This article considers workpiece quality in different drawing craft plan, compare the different productive craft plan and the die structure die's service life. The analysis has obtained the drawing craft to the kind of parabolic drawing drawing quality and the die life influence relations.
拉深加工是薄板料常见的冲压加工方法之一,板料通过模具作用,经塑性变形后,最后获得制品所需要的形状和尺寸。拉深过程中,板料产生塑性变形,材料被转移和重新分布,内部的应力和应变十分复杂,导致拉深过程中的状态难以精确控制。因此,通过控制坯料拉深时的局部应力应变状态来保证拉深件的质量,是取得拉深成功的关键。
本文通过对汽车灯具用类抛物面反射镜拉深工艺的设置及模具结构进行设计和优化,就拉深工艺对制件质量和模具寿命的影响进行对应研究。对雾灯反射镜拉深件的工艺和模具设计,在参照工艺可行性分析结果后,确定采用一道拉深制件主体至规定高度,在拉深后通过安排整形工序来定形制件外形和尺寸的工艺方案。本文所有实验全部依据实际生产进行,研究数据来自生产中的检测和统计。研究过程中对生产中的前大灯反射镜拉深件真实存在的各类质量问题进行分析,并通过改进工艺方案和优化模具结构设计,来解决拉深中制件的质量问题。
研究过程中,拉深工艺方案主要通过调整拉深中部分关键参数或组合、分解部分拉深工艺步骤,以及选择拉深设备等方法来实现,以达到拉深时坯料外部受力均衡的目的。通过修正拉深模工作部分的过渡圆角大小和分布等局部结构,优化坯料拉入凹模时的流动状况;对于前大灯反射镜初次拉深存在的各类问题,在模具对应制件料流不易控制之处,合理设置拉深筋来控制料流,最终解决制件拉深中出现的质量问题。
本文最后通过对不同拉深工艺方案下拉制的制件质量进行对比研究,结合生产中不同工艺方案和模具结构下模具的实际使用寿命,分析得出了拉深工艺对类抛物面拉深件拉深质量和模具寿命的影响关系。
Stamping process as a highly efficient, energy-saving, high material utilization method has a wide range of applications in the modern industrial manufacturing field. To a great extent, stamping technical level determines the capacity of such enterprises in the status in this field. Therefore, detailed and in-depth processing of stamping on the various problems have became common topics in modern manufacturing industry.
The drawing processing is one of the common ramming processing methods of thin sheet, through mold function, after plastic deformation, finally obtains the shape and size which the products need. In the drawing process, the sheet has the plastic deformation, the material is shifted and distributed, because of the complexity of the inside stress and strain, it is difficult to control the condition preciously in the drawing process. Therefore, through controlling the local stress strained condition to guarantee the drawing quality, which is key to obtain the drawing successful.
This article designs and optimizes the drawing process and the die structure of the automobile lamps and lanterns, makes a study of the corresponding research on the drawing craft to the workpiece quality and die life's influence. To fog lamp reflector drawing craft and mold design, considering the craft feasibility analysis result, determines drawing the main body of workpiece to the predetermined altitude, after the drawing comes the setting workpiece contour and the size craft plan through the arrangement reshaping working procedure. All the tests in this article based on the actual production, research data come from the productive examination and the statistics. make an analysis about drawing real existence each kind of quality question of the producing the head lamp reflector process, and through the improvement of craft plan and the optimized of die structural design, solves the quality problem in the drawing workpiece.
In the studies process, through adjust part key parameter of drawing and combining or separating the partial drawing craft step, as well as choosing drawing equipment, the drawing craft achieves the balanced goal when the drawing semifinished materials exterior stress. Through the revision drawing pattern making the excessive fillet size and the distribution as well as other partial structure, optimizes semifinished materials drag into when the lower die the mobile condition;
Before head lamp reflector primary drawing existence's each kind of question, place where the material class in the mold correspondence workpiece is not easy controlled, establishs drawbead to control the material flowing, which finally solves the quality problem in the workpiece drawing . This article considers workpiece quality in different drawing craft plan, compare the different productive craft plan and the die structure die's service life. The analysis has obtained the drawing craft to the kind of parabolic drawing drawing quality and the die life influence relations.
引文
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[24] Daehn Genn S,Shang Jianhui,Vohnout Vincent J. Electromagnetically assisted sheet forming: Enabling difficult shapes and materials by controlled enery distribution[C]. TMS Annual Meeting. Engery Efficient Manufacturing Processes. 2003 :117—128.
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[29] G.N.Gur’yanov. Relative Increase in Axial Stress in The Sizing Zone of a Draw Plate[J]. Metallurgist, 2007,51 (5,6) :334—338.
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[2]朱伟成,徐成林,宋宝阳等.冲压技术发展趋势[J].汽车工艺与材料, 2007,(1): 16—20.
[3]樊延良,刘敬平,王斌修.基于RP技术的快速模具在板料冲压中的应用[M].中国机械工程学会年会论文集, 2005: 362—365.
[4]郎利辉,李涛,安冬洋等.板金液压柔性技术及其产品设计[J].塑性工程学报, 2007, 14 (3) :5—11.
[5]吴伯杰.冲压工艺与模具[M].北京:电子工业出版社, 2004.
[6]李忠明.冲压工艺行业发展现状评述[J].内蒙古石油化工, 2006,(5):86.
[7]李大鑫,张秀棉.模具技术现状与发展趋势综述[J].模具制造, 2005,(2):9-11.
[8]汪祥支.汽车行业四大工艺技术的发展变化[J].汽车工艺与材料, 2007,(9):20—21.
[9] V.F.Matyuk, S.A.Goncharenko, H.Hartmann,etc. Modern State of Nondestructive Testing of Mechanical Properties and Stamping Ability of Steel Sheets in a Manufacturing Technological Flow[J]. Russian Journal of Nondestructive Testing, 2003, 39(5):347—380.
[10]中国模协技术委员会模具国家级新品评审推荐专家组.从模具国家级新品推荐看我国模具技术的发展[J].电加工与模具, 2005,(3): 66-68.
[11]高广军.集成数字化技术在复杂拉深成形模具设计制造中的应用[J].机械工人, 2007, (8) :70—72.
[12] Karld.Majeske, David.w.Glenn. A Hybrid Tool Buy-off Decision Policy for Automotive Sheet Metal Stamping Dies[J]. IIIE Transactions, 2007, (39) :335—346.
[13]王春生.冲压工艺设备的技术进步与发展[J].机械工人, 2006, (12) :10.
[14] Ming Ge,R.Du,Guicai Zhang,etc. Fault diagnosis using support vector machine with an application in sheet metal stamping operations[J]. Mechanical Systems and Signal Processing. 2004, (18) :143—159.
[15]张宝玮.中国锻压技术及装备的现状与发展[J].机械工人(热加工), 2003, (4) :12.
[16] Karld.D.Majeske,Patrick.C.Hammett. Identifying Sources of Variation in Sheet Metal Stamping[J]. The International Journal of Flexible Manufacturing Systems. 2003, (15) :5—18.
[17]王洪俊,范海雁.汽车车身制造中的液力拉深技术[J].锻压装备与制造技术, 2006, (1) :19—21.
[18]吴道建,阳林,孙友松等.板材液压成形技术及其新进展[J].机电工程技术, 2004,33 (7) : 9—14.
[19]模具技术发展呈现三大特点[J].制造技术与机械, 2005, (9) :9.
[20] A.V.Shchedrin, V.V.UI’yanov, V.M.Skoromnov,etc. Making Combination Drawing Methods More Efficient by Controlling Tool Microroughness[J]. 2006, 50 (9,10) :542—547.
[21]李松江.模具制造技术与发展趋势[J],模具制造, 2006, (7) :3—6.
[22]洪慎章.现代模具技术的现状及发展趋势[J].航空制造技术, 2006, (6) :30—32.
[23]胡世光,陈鹤峥.板料冷压成形的工程解析[M].北京:2004.
[24] Daehn Genn S,Shang Jianhui,Vohnout Vincent J. Electromagnetically assisted sheet forming: Enabling difficult shapes and materials by controlled enery distribution[C]. TMS Annual Meeting. Engery Efficient Manufacturing Processes. 2003 :117—128.
[25]邓明,吕琳.冲压成形工艺及模具[M].化学工业出版社.北京:2007.
[26]付宏生.冷冲压成形工艺与模具设计制造[M].化学工业出版社.北京:2005.
[27]成虹.冲压工艺与模具设计[M].电子科技大学出版社.成都:2000.
[28] K Nakamura,T Nakagaws. Sheet metal forming with hydraulic counter pressure in Japan[C]. Annals.CIRP,1987, 36 :191—194.
[29] G.N.Gur’yanov. Relative Increase in Axial Stress in The Sizing Zone of a Draw Plate[J]. Metallurgist, 2007,51 (5,6) :334—338.
[30]李寿萱主编.板金成形原理与工艺[M].西安:西北工业大学出版社, 1985.
[31]曹晓卿.冲压过程质量分析系统[J].系统辩证学学报, 2000,(2): 92—94.
[32] J.S.Sheasby. The effect of steel hardness on the performance of antiwear additives[J]. Wear,1996, 201: 209—216.
[33]李勇,于忠奇,李淑慧等.薄板拉深中拉毛缺陷研究进展[J].塑性工程学报, 2006, 13(4):43—48.
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