CN110705050A - Design method of die surface and die for deep drawing process of inner plate of car door - Google Patents
Design method of die surface and die for deep drawing process of inner plate of car door Download PDFInfo
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Abstract
Description
技术领域technical field
本发明属于模具技术领域,具体的说是一种轿车车门内板拉深工序模面和模具的设计方法。The invention belongs to the technical field of molds, in particular to a method for designing a mold surface and a mold in a drawing process of an inner panel of a car door.
背景技术Background technique
车身具有为驾驶员提供安全的操作环境的功能。因此,车体零件采用承重车体结构,在满足传动系统布置的同时,部分零件作为也要作为车体的骨架结构。车门内板应由许多曲面组成,主要是自由曲面,而且不同的轿车车门内板结构也是不同的,从已经存在的模具中往往找不到完全符合标准的拉深模型。The body has the function of providing a safe operating environment for the driver. Therefore, the car body parts adopt the load-bearing car body structure. While satisfying the arrangement of the transmission system, some parts are also used as the skeleton structure of the car body. The door inner panel should be composed of many curved surfaces, mainly free-form surfaces, and the structure of different car door inner panels is also different. It is often impossible to find a fully standard drawing model from the existing molds.
中国的轿车工业正处在高速发展的阶段,汽车覆盖件具有表面质量以及精度要求高的特点。车门内板是构成驾驶室最重要的一种外覆盖件,它的表面积比较大,成形也十分困难。车门内板并不是千篇一律,它的品种越来越多样,在模具设计与制造方面有很多亟待解决的问题。现有的拉深模具存在结构复杂,上下模座与凸凹模的连接方式过于繁琐,使得拆装与清洗十分不方便,容易造成废料堆积且零件数目过多。同时,现有模具的卸料装置大都单独设计,占据大量空间,使得装配困难。实际生产中压边圈是一整块的,使得大型覆盖件的拉深起皱现象严重。China's car industry is in a stage of rapid development, and automotive panels have the characteristics of high surface quality and high precision requirements. The door inner panel is the most important outer cover that constitutes the cab. It has a relatively large surface area and is very difficult to form. The door inner panel is not the same, its varieties are more and more diverse, and there are many problems to be solved in the mold design and manufacture. The existing deep drawing dies have complex structures, and the connection between the upper and lower die bases and the convex and concave dies is too complicated, which makes disassembly and cleaning very inconvenient, and easily causes waste accumulation and excessive number of parts. At the same time, most of the unloading devices of the existing molds are designed separately, occupying a lot of space, making assembly difficult. In actual production, the blank holder is a single piece, which makes the deep drawing wrinkle of large covering parts serious.
发明内容SUMMARY OF THE INVENTION
本发明提供了一种方法简单的轿车车门内板拉深工序模面和模具的设计方法,既考虑了车身曲面的特点,又考虑了车门原型的特点,针对不同类型车门内板设计相应的拉深工序模面和模具,解决了现有车门内板拉深工序模面和模具存在的上述不足。The invention provides a simple method for designing a die surface and a die for a car door inner panel drawing process, which not only takes into account the characteristics of the body surface, but also the characteristics of the door prototype, and designs corresponding drawing methods for different types of door inner panels. The deep-process die surface and the die solve the above-mentioned shortcomings of the existing vehicle door inner panel deep-drawing process die surface and die.
本发明技术方案结合附图说明如下:The technical scheme of the present invention is described as follows in conjunction with the accompanying drawings:
一种轿车车门内板拉深工序模面和模具的设计方法,该方法包括以下步骤:A method for designing a die surface and a die in a drawing process of an inner panel of a car door, the method comprising the following steps:
步骤一、对给定的车门内板进行工艺分析:车门内板为非对称图形,因此选用激光拼焊钢板进行成对冲压拉深;Step 1. Carry out process analysis on a given door inner panel: the inner door panel is an asymmetrical figure, so the laser tailor-welded steel plate is selected for paired stamping and deep drawing;
步骤二、内部工艺补充:运用CATIA软件的创成式曲面设计模块对车门内板进行工艺补充,在工艺补充过程中如果存在无法直接进行填充的孔洞,需要建立新的曲面,然后再与边界进行桥接;Step 2. Internal process supplement: Use the generative surface design module of CATIA software to supplement the process of the inner panel of the door. If there are holes that cannot be filled directly during the process of supplementary process, a new surface needs to be established, and then the boundary is carried out. bridging;
步骤三、压料面的添加:车门内板为了适应车轮形状,边界会有一部分呈现凹形,对该曲线边界进行压料面的补充时,要采用偏移曲线的方法,然后再对两条曲线之间的部分进行工艺补充;Step 3. Add the binder surface: In order to adapt to the shape of the wheel, the boundary of the inner door panel will be concave. When supplementing the binder surface of the curve boundary, the method of offsetting the curve should be used, and then the two The part between the curves is supplemented by the process;
步骤四、压料面形式的改进:压料面添加完成后,边界形状不规则,难以确定坯料形状,因此需要对其形状进行规整化;Step 4. Improvement of the form of the binder surface: After the binder surface is added, the shape of the boundary is irregular, and it is difficult to determine the shape of the blank, so its shape needs to be regularized;
步骤五、对已经生成的凹模模面进行仿真分析:如果出现严重的拉裂或起皱现象,再对压料面的形式进行改进;Step 5. Perform a simulation analysis on the generated die surface of the die: if serious cracking or wrinkling occurs, improve the form of the binder surface;
步骤六、对已经生成的车门内板拉深工序模面进行模具设计。Step 6: Design the die for the die surface in the deep drawing process of the door inner panel that has been generated.
所述步骤六的具体方法如下:The specific method of the step 6 is as follows:
步骤61)要对模具的压边力与拉深力进行计算:Step 61) To calculate the blank holder force and the deep drawing force of the die:
拉深任何形状工件的压边力公式为:F压=Ap,p=48(z-1.1)D/tσbx10-5,z=1/m,m=d/D;The blank holder force formula for deep drawing of workpieces of any shape is: F pressure =Ap, p=48(z-1.1)D/tσ b x10- 5 , z=1/m, m=d/D;
式中,A为压边圈的面积;p为单位压边力;z为各工序拉深系数m的倒数;σb为毛坯材料的抗拉强度,单位为MPa;t为材料厚度,单位为mm;D为毛坯直径,单位为mm;d为拉深后的直径;In the formula, A is the area of the blank holder; p is the unit blank holder force; z is the reciprocal of the drawing coefficient m of each process; σ b is the tensile strength of the blank material, in MPa; t is the material thickness, in mm; D is the diameter of the blank, in mm; d is the diameter after deep drawing;
拉深力的公式为:F拉=Ltσbk;The formula of the deep drawing force is: F drawing = Ltσ b k;
式中,L为凸模周边长度,单位为mm;t为材料厚度,单位为mm;σb为毛坯材料的抗In the formula, L is the peripheral length of the punch, the unit is mm; t is the material thickness, the unit is mm; σ b is the resistance of the blank material.
拉强度,单位为MPa;k为系数;Tensile strength, the unit is MPa; k is the coefficient;
步骤62)选择压床吨位;查阅冲压手册,根据步骤61)计算的拉深力和压边力,选择的压力机的类型;Step 62) select the tonnage of the press; refer to the stamping manual, and select the type of press according to the drawing force and blank holder force calculated in step 61);
步骤63)根据步骤61)计算所求压边力与拉深力确定装模高度;对于单动压床:压力机的公称力F>F拉+F压;Step 63) According to step 61), calculate the required blank holder force and deep drawing force to determine the height of the die; for a single dynamic press: the nominal force of the press F>F drawing +F pressing ;
根据公称力查阅冲压手册,确定装模高度;Check the stamping manual according to the nominal force to determine the die height;
步骤64)弹簧的选择:由于压边力大,一般的弹簧无法满足要求,所以选择模具专用氮气弹簧;所需要的弹簧数量n=压边力/公称压力,n取整数;Step 64) Spring selection: due to the large blank holder force, general springs cannot meet the requirements, so a special nitrogen gas spring for the mold is selected; the number of springs required is n=blank holder force/nominal pressure, and n is an integer;
步骤65)定位装置的作用是保证毛坯处于一个合适的位置,以保证得到合格的工件,由于工件大,所以选择6个中型孔用定位销;Step 65) The function of the positioning device is to ensure that the blank is in a suitable position to ensure that a qualified workpiece is obtained. Because the workpiece is large, 6 medium-sized holes are selected for positioning pins;
步骤66)采用分块的台阶式压边圈,对于所研究的激光拼焊板零件,零件是由两种厚度的板料拼焊成的,因此将压边圈分为两块,压边圈的分块如图8所示。对分块压边圈,采用三种方案:方案1:不是台阶式压边圈,两边采用不等的压边力,薄侧板料压边力750KN,厚侧压边力350KN;方案2:台阶式压边圈,两边采用相等的压边力,两边的压边力分别为525KN;方案3:台阶式压边圈,两边采用不等的压边力,两边的压边力分别为薄侧材料750KN,厚侧材料350KN。由成形仿真结果可知:方案1不采用台阶式压边圈,而两侧采用不等的压边力,不能改善成形效果;采用台阶式压边圈的方案2和方案3都使薄侧的压边区域的成形性得到改善,褶皱现象减少,方案2采用相等的压边力,薄侧厚度减薄率增大,方案3薄厚两侧采用不相等的恒定压边力,薄侧压边力大而厚侧压边力小,虽然厚度减薄率比原始方案略有降低,但整体成形性较好,并且薄侧压边区域起皱现象大幅度减少。所以选择分块的台阶式压边圈。方案1~方案3的成形结果数值对比如图9所示。Step 66) A block-type step-type blank holder is used. For the laser tailor welded blank parts studied, the parts are made of two kinds of thicknesses of sheet materials. Therefore, the blank holder is divided into two pieces, and the blank holder is divided into two parts. The block is shown in Figure 8. For the block blank holder, three schemes are adopted: Scheme 1: Not a stepped blank holder, with unequal blank holder force on both sides, thin side blank holder force 750KN, thick side blank holder force 350KN; Scheme 2: Step-type blank holder, with equal blank holder force on both sides, the blank holder force on both sides is 525KN respectively; Scheme 3: stepped blank holder ring, with unequal blank holder force on both sides, the blank holder force on both sides is the thin side respectively Material 750KN, thick side material 350KN. It can be seen from the forming simulation results that: Scheme 1 does not use a stepped blank holder, but uses unequal blank holder forces on both sides, which cannot improve the forming effect; Scheme 2 and Scheme 3 using a stepped blank holder both make the thin side blank. The formability of the edge area is improved, and the wrinkling phenomenon is reduced. Scheme 2 adopts equal blank holder force, and the thickness reduction rate of the thin side increases. Scheme 3 adopts unequal constant blank holder force on both sides of the thin and thick side, and the blank holder force on the thin side is large. The thick side blank holder force is small, although the thickness reduction rate is slightly lower than the original solution, but the overall formability is better, and the wrinkling phenomenon in the thin side blank holder area is greatly reduced. Therefore, the block-type step-type blank holder is selected. Figure 9 shows the numerical comparison of the forming results of Schemes 1 to 3.
步骤67)根据具体要求结合步骤61)、步骤62)、步骤63)、步骤64)、步骤65)和步骤66)进行机械结构设计。Step 67) According to specific requirements, combine steps 61), 62), 63), 64), 65) and 66) to design the mechanical structure.
所述步骤二中工艺补充是指除去汽车车身的大型覆盖件以外使用者补充的那部分,在所有的冲压工作完成以后,使用者去除掉这部分材料;添加工艺补充部分主要是为了拉深出符合使用要求的冲压零件;零件内部不能出现孔洞和豁口,孔洞和豁口会导致零件在拉深过程中发生变形,所以需要将孔洞补满,也就是内工艺补充过程;The process supplement in the second step refers to the part supplemented by the user except the large cover of the automobile body. After all the stamping work is completed, the user removes this part of the material; the process supplement is mainly added for the purpose of deep drawing. Stamping parts that meet the requirements of use; no holes and gaps can appear in the parts, holes and gaps will cause the parts to deform during the drawing process, so the holes need to be filled, that is, the internal process replenishment process;
在设计过程中,应该注意防止零件表面出现缺陷;具体操作步骤如下:In the design process, attention should be paid to preventing defects on the surface of the parts; the specific operation steps are as follows:
步骤21)原始的零件中含有很多重复的曲线和曲面,这些曲线和曲面和零件不是一个整体,所以需要把它们删除,然后把原始零件进行整体接合,我们之所以把小突起,螺栓孔删除掉,是为了之后的工序,再者如果存在突起,冲压模具也不方便设计,成本也会增加,冲压过程中还容易出现破裂;选中突起,直接删除该部分;Step 21) The original part contains many repeated curves and surfaces. These curves and surfaces are not a whole with the part, so they need to be deleted, and then the original parts are joined together as a whole. The reason why we deleted the small protrusions and bolt holes , is for the subsequent process, and if there are protrusions, the stamping die is inconvenient to design, the cost will increase, and it is easy to crack during the stamping process; select the protrusion and delete the part directly;
步骤22)把车门内板零件中多余边线和曲面删除或者隐藏;这一部分完成之后用缝合命令把车门内板零件进行整体接合,在这个时候要注意合并的距离CATIA系统默认给出0.001mm,但是车门内板零件中有一些曲面之间的距离是大于0.001mm的,直接进行缝合的话是无法进行操作的;如果出现这种情况,我们只需要将合并距离由0.001mm改为0.1mm即可,然后再对车门内板零件进行整体接合;Step 22) Delete or hide the redundant edges and surfaces in the door inner panel parts; after this part is completed, use the stitching command to join the door inner panel parts as a whole. At this time, pay attention to the merged distance The CATIA system gives 0.001mm by default, but The distance between some curved surfaces in the door inner panel parts is greater than 0.001mm, and it is impossible to sew directly; if this happens, we only need to change the merging distance from 0.001mm to 0.1mm, Then the door inner panel parts are integrally joined;
步骤23)整体接合之后,就可以对车门内板零件进行内工艺补充部分的设计;添加内工艺补充部分之前,首先要建立一个CATIA子目录,这样后续的步骤就全部存放在这个子目录中,如果以后需要对车门内板零件的某一个工艺补充进行修改,就可以直接在这个子目录下进行;Step 23) After the overall bonding, the interior process supplementary part can be designed for the door inner panel parts; before adding the internal process supplementary part, a CATIA subdirectory must be established first, so that the subsequent steps are all stored in this subdirectory, If you need to modify a certain process supplement of the door inner panel parts in the future, you can do it directly in this subdirectory;
步骤24)车门内板零件上有许多用于定位的孔洞,进行内部工艺补充,主要是在零件上补孔,然后将所有工艺补充与整体的车门内板零件进行缝合;Step 24) There are many holes for positioning on the door inner panel parts, and internal process supplements are carried out, mainly by filling holes on the parts, and then all process supplements are stitched with the overall door inner panel parts;
步骤25)车门内板零件中间存在一个孔,主要用于玻璃升降器等配件的安装,该孔的边界线并不在一个平面上,如果直接进行填充会出现表面凹凸不平的现象;在这种情况下,先直接进行填充,检查填充部位的表面质量,如果没有凸包存在,可以继续对其进行操作,如果存在凸包,就要自己建立一个空间曲面,然后通过桥接把它与孔的四周连接到一起;Step 25) There is a hole in the middle of the door inner panel part, which is mainly used for the installation of accessories such as glass lifters. The boundary line of the hole is not on a plane. If filling is performed directly, the surface will be uneven; in this case If there is no convex hull, you can continue to operate on it. If there is a convex hull, you must create a space surface by yourself, and then connect it to the surrounding of the hole by bridging come together;
步骤26)车门内板中有一些部位是无法直接进行桥接的,在这种情况下,可以建立一个新曲面分别与它们进行桥接或者对它们进行切割,然后重新进行桥接;首先选择一个合适的平面,画一个面积比较大的规则图形,然后将其拉深,使它完全与零件相交,再使用CATIA分割命令把多余的部分切割掉,再进行倒角使其圆滑过渡。Step 26) There are some parts of the door inner panel that cannot be directly bridged. In this case, you can create a new surface to bridge them or cut them, and then re-bridge; first select a suitable plane , draw a regular graphic with a relatively large area, and then draw it so that it completely intersects with the part, then use the CATIA division command to cut off the excess part, and then perform chamfering to make it a smooth transition.
所述步骤三的具体方法如下:The specific method of the third step is as follows:
步骤31)采用CATIA软件曲面建模中的创成式曲面设计模块中的外插延伸指令,将零件的非对称边界延伸300mm,对称边界延伸50mm,为了使压料面平滑,相邻地延伸部分可以通过填充命令或者桥接命令进行连接;相隔较远的延伸部分经过填充后可能会出现黑线,这是由于曲面不连续造成的;采用内工艺补充时的样条线连接,然后再进行填充的方法,可以提高压料面部分的曲面连续性,这样就会使黑线大大减少,同时对不容易进行拉深的曲面边界进行提取以及平移,然后把其中的空余部分填充完整,这时候要经过反复修改,改变曲率以及改变切线等操作来避免黑线的出现;因为仿真时候要保证整个零件上没有黑线,所以压料面的处理过程是非常重要的;圆角部位不能通过直接拉深的方式成型,只能通过自己画出符合要求的桥接线,注意要保证连接的流畅,然后再进行填充;Step 31) Use the extrapolation extension command in the generative surface design module in the surface modeling of CATIA software to extend the asymmetric boundary of the part by 300mm and the symmetrical boundary by 50mm. In order to make the pressing surface smooth, extend parts adjacent to each other. It can be connected by filling command or bridging command; black lines may appear after filling the far apart extension, which is caused by the discontinuity of the surface; the spline connection when the internal process is supplemented is used, and then filled. This method can improve the surface continuity of the binder surface part, which will greatly reduce the black lines, and at the same time extract and translate the surface boundary that is not easy to draw, and then fill in the empty part. Repeatedly modify, change the curvature and change the tangent to avoid the appearance of black lines; because it is necessary to ensure that there are no black lines on the entire part during simulation, the processing process of the binder surface is very important; the rounded parts cannot be drawn directly. Only by drawing the bridge line that meets the requirements by yourself, pay attention to ensure the smooth connection, and then fill it;
步骤32)接下来就是对我们填充的部分以及原始零件进行整体缝合,如果两个曲面的距离大于1mm比较大的话,需要按照步骤31)的方法,然后才可以填充,操作完成之后,使用提取边界的操作进行检查,直到整个零件都没有黑线;Step 32) The next step is to stitch the parts we filled and the original parts as a whole. If the distance between the two surfaces is greater than 1mm, you need to follow the method of step 31) before filling. After the operation is completed, use the extraction boundary operation to check until the entire part is free of black lines;
步骤33)进入零件的草图编辑模式,选择合适的位置画一个平面,我们所画平面的形状与零件边缘一致,然后退出草图编辑界面,通过拉深命令对我们所画的平面边界进行拉深,拉深的方向应该选择零件所在的方向,注意拉深的深度要大于零件的深度,这样才能把整个零件都放在该矩形中;将拉深件以外多余的部分,修剪命令去除掉;然后,将画出的矩形框隐藏即可;最后,隐藏掉草图中多余的线和面,保证零件上一条黑线也没有;Step 33) Enter the sketch editing mode of the part, select a suitable position to draw a plane, the shape of the plane we draw is consistent with the edge of the part, then exit the sketch editing interface, and use the deep drawing command to draw the plane boundary we drew, The direction of deep drawing should be selected in the direction of the part. Note that the depth of deep drawing should be greater than the depth of the part, so that the entire part can be placed in the rectangle; remove the excess part outside the deep drawing part with the trim command; then, Just hide the drawn rectangular frame; finally, hide the extra lines and surfaces in the sketch to ensure that there is no black line on the part;
步骤34)车门内板为了适应车轮形状,边界会有一部分呈现凹形,对该曲线边界进行压料面的补充时,要采用偏移曲线的方法,然后再对两条曲线之间的部分进行工艺补充。Step 34) In order to adapt to the shape of the wheel, a part of the boundary of the inner door panel will be concave. When supplementing the binder surface of the curved boundary, the method of offsetting the curve should be used, and then the part between the two curves should be adjusted. Process Supplements.
本发明的有益效果为:The beneficial effects of the present invention are:
1)拉深工序模面采用成对拉深,大大提高了生产效率。1) In the drawing process, the die surface is drawn in pairs, which greatly improves the production efficiency.
2)使用该方法设计的拉深坯料大致形状与拉深工序件一致,节省了原材料,因此,大大减少了生产成本。2) The rough shape of the drawing blank designed by this method is consistent with the drawing process part, which saves raw materials and thus greatly reduces the production cost.
3)该方法适合各种覆盖件的模面设计,有很强的推广性。3) This method is suitable for the mold surface design of various covering parts, and has strong promotion.
附图说明Description of drawings
图1为本发明的设计流程图;Fig. 1 is the design flow chart of the present invention;
图2为本发明步骤五的仿真结果附图;Fig. 2 is the simulation result accompanying drawing of step 5 of the present invention;
图3为按照本方法设计的模具的正视图;Fig. 3 is the front view of the mould designed according to this method;
图4为按照本方法设计的模具的左视图;Fig. 4 is the left side view of the mould designed according to this method;
图5为按照本方法设计的模具装配图俯视图,其中左半图为拆掉上模的下模俯视图,右半图为拆掉下模的上模俯视图;5 is a top view of a mold assembly view designed according to the present method, wherein the left half of the diagram is a top view of the lower mold with the upper mold removed, and the right half of the diagram is a top view of the upper mold with the lower mold removed;
图6为按照本方法设计的模具的推销结构示意图。FIG. 6 is a schematic diagram of the push-pull structure of the mold designed according to the present method.
图7为图6中A—A处剖视图;Figure 7 is a sectional view at A-A in Figure 6;
图8为压边圈分块示意图;Fig. 8 is a block diagram of a blank holder;
图9为几种压边圈方案的成形结果数值对比;Figure 9 is a numerical comparison of the forming results of several blank holder schemes;
图10为轿车车门内板拉深工序件正视图;Figure 10 is a front view of the drawing process part of the inner panel of the car door;
图11为轿车车门内板拉深工序件左视图;Figure 11 is a left side view of a car door inner panel drawing process part;
图12为轿车车门内板拉深工序件俯视图。FIG. 12 is a top view of the drawing process part of the inner panel of the car door.
图中:1、上模座;2、凹模;3、上模座与凹模连接螺钉;4、凸模;5、压边圈;6、定位销;7、导套;8、导柱;9、氮气弹簧;10、下模座;11、卸料螺钉;12、凸模与下模座连接螺钉;13、限位块;14、推销。In the picture: 1. Upper die seat; 2. Concave die; 3. Connecting screw between upper die seat and female die; 4. Punch die; 5. Holder ring; 6. Positioning pin; 7. Guide sleeve; 8. Guide post ; 9, nitrogen gas spring; 10, lower die base; 11, discharge screw; 12, connecting screw between punch and lower die base; 13, limit block; 14, sales promotion.
具体实施方式Detailed ways
实施例Example
参阅图1,步骤一、对给定的车门内板进行工艺分析:车门内板为非对称图形,因此选用采用0.7mm厚的ST06Z钢板进行成对冲压拉深,这样可以大幅提高生产率,更加适合工业化需求。Refer to Figure 1, step 1. Perform process analysis on a given door inner panel: The door inner panel is an asymmetrical pattern, so 0.7mm thick ST06Z steel plate is selected for paired stamping and drawing, which can greatly improve productivity and is more suitable for Industrialization needs.
步骤二、内部工艺补充:运用CATIA软件的创成式曲面设计模块对车门内板进行工艺补充,在工艺补充过程中遇见无法直接进行填充的孔洞,需要建立新的曲面,然后再与边界进行桥接;Step 2. Internal process supplement: Use the generative surface design module of CATIA software to supplement the process of the inner panel of the door. During the process of process supplement, if there are holes that cannot be filled directly, a new surface needs to be established, and then bridged with the boundary ;
所述步骤二中工艺补充是指除去汽车车身的大型覆盖件以外使用者补充的那部分,在所有的冲压工作完成以后,使用者去除掉这部分材料;添加工艺补充部分主要是为了拉深出符合使用要求的冲压零件;零件内部不能出现孔洞和豁口,孔洞和豁口会导致零件在拉深过程中发生变形,所以需要将孔洞补满,也就是内工艺补充过程;The process supplement in the second step refers to the part supplemented by the user except the large cover of the automobile body. After all the stamping work is completed, the user removes this part of the material; the process supplement is mainly added for the purpose of deep drawing. Stamping parts that meet the requirements of use; no holes and gaps can appear in the parts, holes and gaps will cause the parts to deform during the drawing process, so the holes need to be filled, that is, the internal process replenishment process;
在设计过程中,应该注意防止零件表面缺陷的工艺补充问题;具体操作步骤如下:In the design process, attention should be paid to the process supplementary problem to prevent surface defects of parts; the specific operation steps are as follows:
步骤21)原始的零件中含有很多重复的曲线和曲面,这些曲线和曲面和零件不是一个整体,所以需要把它们删除,然后把原始零件进行整体接合,我们之所以把小突起,螺栓孔删除掉,是为了之后的工序,再者如果存在突起,冲压模具也不方便设计,成本也会增加,冲压过程中还容易出现破裂;选中突起,直接删除该部分;Step 21) The original part contains many repeated curves and surfaces. These curves and surfaces are not a whole with the part, so they need to be deleted, and then the original parts are joined together as a whole. The reason why we deleted the small protrusions and bolt holes , is for the subsequent process, and if there are protrusions, the stamping die is inconvenient to design, the cost will increase, and it is easy to crack during the stamping process; select the protrusion and delete the part directly;
步骤22)把车门内板零件中多余边线和曲面删除或者隐藏;这一部分完成之后用缝合命令把车门内板零件进行整体接合,在这个时候要注意合并的距离CATIA系统默认给出0.001mm,但是车门内板零件中有一些曲面之间的距离是大于0.001mm的,直接进行缝合的话是无法进行操作的;如果出现这种情况,我们只需要将合并距离由0.001mm改为0.1mm即可,然后再对车门内板零件进行整体接合;Step 22) Delete or hide the redundant edges and surfaces in the door inner panel parts; after this part is completed, use the stitching command to join the door inner panel parts as a whole. At this time, pay attention to the merged distance The CATIA system gives 0.001mm by default, but The distance between some curved surfaces in the door inner panel parts is greater than 0.001mm, and it is impossible to sew directly; if this happens, we only need to change the merging distance from 0.001mm to 0.1mm, Then the door inner panel parts are integrally joined;
步骤23)整体接合之后,就可以对车门内板零件进行内工艺补充部分的设计;添加内工艺补充部分之前,首先要建立一个CATIA子目录,这样后续的步骤就全部存放在这个子目录中,如果以后需要对车门内板零件的某一个工艺补充进行修改,就可以直接在这个子目录下进行;Step 23) After the overall bonding, the interior process supplementary part can be designed for the door inner panel parts; before adding the internal process supplementary part, a CATIA subdirectory must be established first, so that the subsequent steps are all stored in this subdirectory, If you need to modify a certain process supplement of the door inner panel parts in the future, you can do it directly in this subdirectory;
步骤24)车门内板零件上有许多用于定位的孔洞,采用内部工艺补充,主要是在零件上补孔,将所有工艺补充与整体的车门内板零件进行缝合;Step 24) There are many holes for positioning on the door inner panel parts, which are supplemented by internal processes, mainly by filling holes on the parts, and stitching all process supplements with the overall door inner panel parts;
步骤25)车门内板零件中间存在一个直径为730mm左右的孔,主要用于玻璃升降器等配件的安装,该孔的边界线并不在一个平面上,如果直接进行填充会出现表面凹凸不平的现象;在这种情况下,先直接进行填充,检查填充部位的表面质量,如果没有凸包存在,可以继续对其进行操作,如果存在凸包,就要自己建立一个空间曲面,然后通过桥接把它与孔的四周连接到一起;Step 25) There is a hole with a diameter of about 730mm in the middle of the door inner panel part, which is mainly used for the installation of accessories such as glass lifters. The boundary line of the hole is not on a plane. If it is filled directly, the surface will be uneven. ; In this case, first fill directly, check the surface quality of the filling part, if there is no convex hull, you can continue to operate on it, if there is a convex hull, you must create a space surface by yourself, and then bridge it. connected with the perimeter of the hole;
步骤26)车门内板中有一些部位是无法直接进行桥接的,在这种情况下,可以建立一个新曲面分别与它们进行桥接或者对它们进行切割,然后重新进行桥接;首先选择一个合适的平面,画一个面积比较大的规则图形,然后使用将其拉深,使它完全与零件相交,再使用分割命令把多余的部分切割掉,然后再进行倒角使其圆滑过渡。Step 26) There are some parts of the door inner panel that cannot be directly bridged. In this case, you can create a new surface to bridge them or cut them, and then re-bridge; first select a suitable plane , draw a regular graphic with a relatively large area, and then use it to draw it so that it completely intersects with the part, and then use the split command to cut off the excess part, and then perform chamfering to make it a smooth transition.
步骤三、压料面的添加:车门内板为了适应车轮形状,边界会有一部分呈现凹形,对该曲线边界进行压料面的补充时,要采用偏移曲线的方法,然后再对两条曲线之间的部分进行工艺补充;Step 3. Add the binder surface: In order to adapt to the shape of the wheel, the boundary of the inner door panel will be concave. When supplementing the binder surface of the curve boundary, the method of offsetting the curve should be used, and then the two The part between the curves is supplemented by the process;
所述步骤三的具体方法如下:The specific method of the third step is as follows:
步骤31)采用CATIA软件曲面建模中的创成式曲面设计模块中的外插延伸指令,将零件的非对称边界延伸300mm,对称边界延伸50mm,为了使压料面平滑,相邻地延伸部分可以通过填充命令或者桥接命令进行连接;相隔较远的延伸部分经过填充后可能会出现黑线,这是由于曲面不连续造成的;采用内工艺补充时的样条线连接,然后再进行填充的方法,可以提高压料面部分的曲面连续性,这样就会使黑线大大减少,同时对不容易进行拉深的曲面边界进行提取以及平移,然后把其中的空余部分填充完整,这时候要经过反复修改,改变曲率以及改变切线等操作来避免黑线的出现;因为仿真时候要保证整个零件上没有黑线,所以压料面的处理过程是非常重要的;圆角部位不能通过直接拉深的方式成型,只能通过自己画出符合要求的桥接线,注意要保证连接的流畅,然后再进行填充;Step 31) Use the extrapolation extension command in the generative surface design module in the surface modeling of CATIA software to extend the asymmetric boundary of the part by 300mm and the symmetrical boundary by 50mm. In order to make the pressing surface smooth, extend parts adjacent to each other. It can be connected by filling command or bridging command; black lines may appear after filling the far apart extension, which is caused by the discontinuity of the surface; the spline connection when the internal process is supplemented is used, and then filled. This method can improve the surface continuity of the binder surface part, which will greatly reduce the black lines, and at the same time extract and translate the surface boundary that is not easy to draw, and then fill in the empty part. Repeatedly modify, change the curvature and change the tangent to avoid the appearance of black lines; because it is necessary to ensure that there are no black lines on the entire part during simulation, the processing process of the binder surface is very important; the rounded parts cannot be drawn directly. Only by drawing the bridge line that meets the requirements by yourself, pay attention to ensure the smooth connection, and then fill it;
步骤32)接下来就是对我们填充的部分以及原始零件进行整体缝合,如果两个曲面的距离比较大的话,需要按照第一条的方法,然后才可以填充,操作完成之后,使用提取边界的操作进行检查,直到整个零件都没有黑线;Step 32) The next step is to stitch the parts we filled and the original parts as a whole. If the distance between the two surfaces is relatively large, you need to follow the first method before filling. After the operation is completed, use the operation of extracting the boundary. Check until the entire part is free of black lines;
步骤33)进入零件的草图编辑模式,选择合适的位置画一个平面,我们所画平面的形状与零件边缘一致,然后退出草图编辑界面,通过拉深命令对我们所画的平面边界进行拉深,拉深的方向应该选择零件所在的方向,注意拉深的深度要大于零件的深度,这样才能把整个零件都放在该矩形中;将拉深件以外多余的部分,修剪命令去除掉;然后,将画出的矩形框隐藏即可;最后,隐藏掉草图中多余的线和面,保证零件上一条黑线也没有;Step 33) Enter the sketch editing mode of the part, select a suitable position to draw a plane, the shape of the plane we draw is consistent with the edge of the part, then exit the sketch editing interface, and use the deep drawing command to draw the plane boundary we drew, The direction of deep drawing should be selected in the direction of the part. Note that the depth of deep drawing should be greater than the depth of the part, so that the entire part can be placed in the rectangle; remove the excess part outside the deep drawing part with the trim command; then, Just hide the drawn rectangular frame; finally, hide the extra lines and surfaces in the sketch to ensure that there is no black line on the part;
步骤34)车门内板为了适应车轮形状,边界会有一部分呈现凹形,对该曲线边界进行压料面的补充时,要采用偏移曲线的方法,然后再对两条曲线之间的部分进行工艺补充。Step 34) In order to adapt to the shape of the wheel, a part of the boundary of the inner door panel will be concave. When supplementing the binder surface of the curved boundary, the method of offsetting the curve should be used, and then the part between the two curves should be adjusted. Process Supplements.
步骤四、压料面形式的改进:压料面添加完成后,边界形状不规则,难以确定坯料形状,因此需要对其形状进行规整化;Step 4. Improvement of the form of the binder surface: After the binder surface is added, the shape of the boundary is irregular, and it is difficult to determine the shape of the blank, so its shape needs to be regularized;
步骤五、对已经生成的凹模模面进行仿真分析:如果出现严重的拉裂或起皱现象,再对压料面的形式进行改进;仿真结果参与图5。该仿真结果输出图为色阶图,经过处理呈现图5的效果。从图中可以看出,该零件成型所需部位均在安全区域内,压料面部分虽然有起皱倾向,但是后期可以通过切除、整形等手段去除影响,因此,对于压料面的添加以及内部工艺补充来说,是合格的,可以继续进行拉深工序模具的设计。Step 5. Perform simulation analysis on the generated die surface of the die: if serious cracking or wrinkling occurs, the form of the binder surface should be improved; the simulation results are shown in Figure 5. The output graph of the simulation result is a gradation graph, and the effect shown in Figure 5 is presented after processing. It can be seen from the figure that the parts required for forming the part are all in the safe area. Although the pressing surface has a tendency to wrinkle, the influence can be removed by cutting, shaping and other means in the later stage. Therefore, for the addition of the pressing surface and In addition, the internal process is qualified, and the design of the deep drawing process mold can be continued.
步骤六、对已经生成的车门内板拉深工序模面进行模具设计。Step 6: Design the die for the die surface in the deep drawing process of the door inner panel that has been generated.
所述步骤六的具体方法如下:The specific method of the step 6 is as follows:
步骤61)要对压边圈的压边力与拉深力进行计算:Step 61) To calculate the blank holder force and the deep drawing force of the blank holder:
拉深任何形状工件的压边力公式为:F压=Ap,p=48(z-1.1)D/tσbx10-5,z=1/m,m=d/D;The blank holder force formula for deep drawing of workpieces of any shape is: F pressure =Ap, p=48(z-1.1)D/tσ b x10- 5 , z=1/m, m=d/D;
式中,A为压边圈的面积;p为单位压边力;z为各工序拉深系数m的倒数;σb为毛坯材料的抗拉强度,单位为MPa;t为材料厚度,单位为mm;D为毛坯直径,单位为mm;d为拉深后的直径。In the formula, A is the area of the blank holder; p is the unit blank holder force; z is the reciprocal of the drawing coefficient m of each process; σ b is the tensile strength of the blank material, in MPa; t is the material thickness, in mm; D is the diameter of the blank, in mm; d is the diameter after deep drawing.
本实施例中A=2000x1655-2x1/2x1020x1020-725x725-2x1/2x725x725=1218350mm2;In this embodiment, A=2000x1655-2x1/2x1020x1020-725x725-2x1/2x725x725=1218350mm2;
m=d/D=2000/2420=0.83,Z=1/m=1/0.83=1.21;m=d/D=2000/2420=0.83, Z=1/m=1/0.83=1.21;
σb=318.2Mpa;σ b =318.2Mpa;
t=0.7mm;t=0.7mm;
D=2420mm;D=2420mm;
P=4.5Mpa;P=4.5Mpa;
F压=1218350x4.5=5482.58kN;F pressure =1218350x4.5=5482.58kN;
拉深力的公式为:F拉=Ltσbk;The formula of the deep drawing force is: F drawing = Ltσ b k;
式中,L为凸模周边长度,单位为mm;t为材料厚度,单位为mm;σb为毛坯材料的抗拉强度,单位为MPa;k为系数;In the formula, L is the peripheral length of the punch, the unit is mm; t is the material thickness, the unit is mm; σ b is the tensile strength of the blank material, the unit is MPa; k is the coefficient;
本实施例中L=(945+725x1.21)x2=3644.5mm;In this embodiment, L=(945+725x1.21)x2=3644.5mm;
T=0.7mm;T=0.7mm;
σb=318.2MPa;σb = 318.2MPa ;
kσ=0.8;k σ = 0.8;
F=3644.5x0.7x318.2x0.8=649.42kN;F=3644.5x0.7x318.2x0.8=649.42kN;
取拉深力为F=650kN;Take the drawing force as F=650kN;
步骤62)选择压床吨位;查阅冲压手册,根据步骤61)计算的拉深力和压边力,Step 62) Select the tonnage of the press; refer to the stamping manual, according to the drawing force and blank holder force calculated in step 61),
车门内板属于大型且结构复杂冲压件,公称力为6100kN,所以选择闭式压力机而非开式机械压力机,开式机械压力机一般只能满足2500kN以下的公称力。本发明最大装模高度为950mm。闭式单点压力机一般只能满足装模高度750mm以下的模具。综上,选择JH36-800闭式双点压力机。这种压力机具有刚性好,精度高的优点。The door inner panel is a large and complex stamping part with a nominal force of 6100kN. Therefore, a closed type press is selected instead of an open type mechanical press. Generally, an open type mechanical press can only meet the nominal force below 2500kN. The maximum die height of the present invention is 950mm. Closed single-point presses generally can only meet molds with a mold height of less than 750mm. To sum up, choose JH36-800 closed double-point press. This press has the advantages of good rigidity and high precision.
步骤63)根据步骤61)计算所求压边力与拉深力确定装模高度;对于单动压床:压力机的公称力F>F拉+F压=5450+650=6100kN;查阅冲压手册,可取最大装模高度为950mm。Step 63) Calculate the required blank holder force and deep drawing force according to step 61) to determine the die height; for a single-moving press: the nominal force of the press F>F drawing +F pressing =5450+650=6100kN; refer to the stamping manual , the maximum die height is 950mm.
步骤64)弹簧的选择:由于压边力大,一般的弹簧无法满足要求,所以选择模具专用氮气弹簧;所需要的弹簧数量n=压边力/公称压力=5450/200=27.25,取n=28,因为压边圈底部距离下模座上部为120mm。所以,选择MQC 200.0-125-328。Step 64) Spring selection: Due to the large blank holder force, general springs cannot meet the requirements, so a special nitrogen gas spring for the mold is selected; the required number of springs n= blank holder force/nominal pressure=5450/200=27.25, take n= 28, because the bottom of the blank holder is 120mm from the upper part of the lower die holder. So, choose MQC 200.0-125-328.
步骤65)定位装置的作用是保证毛坯处于一个合适的位置,以保证得到合格的工件,由于工件大,所以选择6个中型孔用定位销;Step 65) The function of the positioning device is to ensure that the blank is in a suitable position to ensure that a qualified workpiece is obtained. Because the workpiece is large, 6 medium-sized holes are selected for positioning pins;
步骤66)采用分块的台阶式压边圈,对于所研究的激光拼焊板零件,零件是由两种厚度的板料拼焊成的,因此将压边圈分为两块,压边圈的分块如图8所示。对分块压边圈,采用三种方案:方案1:不是台阶式压边圈,两边采用不等的压边力,薄侧板料压边力750KN,厚侧压边力350KN;方案2:台阶式压边圈,两边采用相等的压边力,两边的压边力分别为525KN;方案3:台阶式压边圈,两边采用不等的压边力,两边的压边力分别为薄侧材料750KN,厚侧材料350KN。由成形仿真结果可知:方案1不采用台阶式压边圈,而两侧采用不等的压边力,不能改善成形效果;采用台阶式压边圈的方案2和方案3都使薄侧的压边区域的成形性得到改善,褶皱现象减少,方案2采用相等的压边力,薄侧厚度减薄率增大,方案3薄厚两侧采用不相等的恒定压边力,薄侧压边力大而厚侧压边力小,虽然厚度减薄率比原始方案略有降低,但整体成形性较好,并且薄侧压边区域起皱现象大幅度减少。所以选择分块的台阶式压边圈。方案1~方案3的成形结果数值对比如图9所示。Step 66) A block-type step-type blank holder is used. For the laser tailor welded blank parts studied, the parts are made of two kinds of thicknesses of sheet materials. Therefore, the blank holder is divided into two pieces, and the blank holder is divided into two parts. The block is shown in Figure 8. For the block blank holder, three schemes are adopted: Scheme 1: Not a stepped blank holder, with unequal blank holder force on both sides, thin side blank holder force 750KN, thick side blank holder force 350KN; Scheme 2: Step-type blank holder, with equal blank holder force on both sides, the blank holder force on both sides is 525KN respectively; Scheme 3: stepped blank holder ring, with unequal blank holder force on both sides, the blank holder force on both sides is the thin side respectively Material 750KN, thick side material 350KN. It can be seen from the forming simulation results that: Scheme 1 does not use a stepped blank holder, but uses unequal blank holder forces on both sides, which cannot improve the forming effect; Scheme 2 and Scheme 3 using a stepped blank holder both make the thin side blank. The formability of the edge area is improved, and the wrinkling phenomenon is reduced. Scheme 2 adopts equal blank holder force, and the thickness reduction rate of the thin side increases. Scheme 3 adopts unequal constant blank holder force on both sides of the thin and thick side, and the blank holder force on the thin side is large. The thick side blank holder force is small, although the thickness reduction rate is slightly lower than the original solution, but the overall formability is better, and the wrinkling phenomenon in the thin side blank holder area is greatly reduced. Therefore, the block-type step-type blank holder is selected. Figure 9 shows the numerical comparison of the forming results of Schemes 1 to 3.
步骤67)根据具体要求结合步骤61)、步骤62)、步骤63)、步骤64)、步骤65)和步骤66)进行机械结构设计。Step 67) According to specific requirements, combine steps 61), 62), 63), 64), 65) and 66) to design the mechanical structure.
参阅图3—图8,根据上述方法设计的模具的具体结构为:该模具包括上模座1、凹模2、上模座与凹模连接螺钉3、凸模4、压边圈5、定位销6、导套7、导柱8、氮气弹簧9、下模座10、卸料螺钉11、凸模与下模座连接螺钉12、限位块13和推销14。Referring to Fig. 3-Fig. 8, the concrete structure of the mould designed according to the above-mentioned method is: this mould comprises an upper die holder 1, a female die 2, an upper die holder and a female die connecting screw 3, a punch 4, a blank holder 5, a positioning Pin 6 , guide sleeve 7 , guide post 8 , nitrogen gas spring 9 , lower die base 10 , discharge screw 11 , connecting screw 12 between the punch and the lower die base, limit block 13 and push pin 14 .
所述凹模2通过上模座与凹模连接螺钉3与上模座1连接;所述上模座与凹模连接螺钉3有四个;所述凸模4通过凸模与下模座连接螺钉12与下模座10连接,所述凸模与下模座连接螺钉12有四个;所述上模座1与下模座10通过导柱8连接;凹模2与凸模4可通过连接螺钉直接与之相连,解决了上下模座与凸凹模的连接方式过于繁琐,拆装与清洗不方便的问题。所述导套7套在导柱8上;所述氮气弹簧9固定在下模座10中;所述压边圈5与下模座10通过卸料螺钉11连接;所述定位销6和压边圈5过盈配合;压边圈可起到卸料作用,防止坯料卡在凸模4上;所述限位块13有四个,均为圆柱形。所述限位块13固定在下模座10上;所述推销14固定在凹模2中。所述上模座1和下模座10的两侧均开有凹槽。所述压边圈5采用分块式压边圈。The female mold 2 is connected to the upper mold seat 1 through the upper mold seat and the female mold connecting screw 3; the upper mold seat and the female mold connecting screw 3 have four; The screws 12 are connected with the lower die base 10, and the punch and the lower die base have four connecting screws 12; the upper die base 1 and the lower die base 10 are connected through the guide post 8; the female die 2 and the punch 4 can pass through The connecting screw is directly connected with it, which solves the problem that the connection mode of the upper and lower die bases and the male and female dies is too complicated, and the disassembly, assembly and cleaning are inconvenient. The guide sleeve 7 is sleeved on the guide post 8; the nitrogen gas spring 9 is fixed in the lower die base 10; the blank holder ring 5 is connected with the lower die holder 10 by the unloading screw 11; the positioning pin 6 and the blank holder The ring 5 has an interference fit; the blank holder can play the role of unloading to prevent the blank from being stuck on the punch 4; there are four limit blocks 13, all of which are cylindrical. The limiting block 13 is fixed on the lower die base 10 ; the push pin 14 is fixed in the female die 2 . Both sides of the upper die base 1 and the lower die base 10 are provided with grooves. The edge blank holder 5 adopts a block type blank holder ring.
轿车车门内板采用激光拼焊钢板进行冲压拉深,经计算,取压边力F=5450kN,拉深力为F=650kN,本实施例选择的压力机是闭式双点压力机。对于单动压床:F>F拉+F压=5450kN+650kN=6100kN,取最大装模高度H2为950mm。所需要的氮气弹簧9的数量N=压边力/公称压力=5450/200=27.25,取N=28,可以采用型号MQC 200.0-125-328。所述限位块13为4个圆柱形45号钢零件,可以保证合模时的平稳且不至于破坏下模座的强度和刚度。所述推销一共有四个,推销由固定盖板、弹簧、推杆以及四个连接螺钉组成。螺钉将盖板固定在凹模中,推杆在弹簧的作用下可以上下移动。连接螺钉为M5,采用GB60-76;所述压边圈5底部距离下模座10的上部距离为120mm。推销14可防止坯料卡在凹模2中,解决了容易造成废料堆积且零件数目过多,占用空间较大的问题;所述压边圈5采用分块式压边圈,整体成形性较好,并且薄侧压边区域起皱现象大幅度减少,解决了现有生产模具起皱现象严重的问题。The inner panel of the car door is drawn by laser tailor-welded steel plate. After calculation, the blank holder force is F=5450kN, and the drawing force is F=650kN. The press selected in this embodiment is a closed double-point press. For a single dynamic press: F>F pull+F pressure=5450kN+650kN=6100kN, take the maximum die height H2 as 950mm. The required quantity of nitrogen gas springs 9 is N=blank holder force/nominal pressure=5450/200=27.25, taking N=28, the model MQC 200.0-125-328 can be used. The limiting blocks 13 are four cylindrical 45# steel parts, which can ensure the stability of the mold clamping without damaging the strength and rigidity of the lower mold base. There are four sales pitches in total, and the sales pitches consist of a fixed cover plate, a spring, a push rod and four connecting screws. The cover plate is fixed in the die by the screw, and the push rod can move up and down under the action of the spring. The connecting screw is M5 and adopts GB60-76; the distance between the bottom of the blank holder 5 and the upper part of the lower die base 10 is 120mm. The push-button 14 can prevent the blank from being stuck in the die 2, which solves the problem that waste is easily accumulated, the number of parts is too large, and the space is occupied. , and the wrinkling phenomenon in the thin side blank holder area is greatly reduced, which solves the serious problem of wrinkling in the existing production mold.
该模具的工作原理为:The working principle of the mold is:
(1):将坯料放置在定位销6的限定范围中,上模座1带动凹模2向下运动,在此过程中,氮气弹簧9进行压缩,卸料螺钉11向下运动,推销14中的推杆向上运动,使推销中的弹簧压缩。(1): Place the blank in the limited range of the positioning pin 6, and the upper die seat 1 drives the female die 2 to move downward. During this process, the nitrogen gas spring 9 is compressed, the unloading screw 11 moves downward, and the push-button 14 moves downward. The push rod moves upward, compressing the spring in the push rod.
(2):当压边圈5向下运动接触到限位块13时,合模完成。(2): When the blank holder 5 moves downward and contacts the limit block 13, the mold clamping is completed.
(3):合模完成后,上模座1向上运动,氮气弹簧9带动压边圈5回弹,防止坯料卡在凸模4上,与此同时推销14中的弹簧复位,使推销中的推杆向下顶出,防止坯料卡在凹模2中。至此,拉深过程完成。车门内板拉深工序件见附图10—12。(3): After the mold clamping is completed, the upper mold base 1 moves upward, and the nitrogen gas spring 9 drives the edge holder 5 to rebound to prevent the blank from being stuck on the punch 4. At the same time, the spring in the pusher 14 is reset, so that the The push rod is ejected downward to prevent the blank from being stuck in the die 2. At this point, the deep drawing process is completed. The drawing process parts of the inner panel of the door are shown in Figures 10-12.
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