CN114453519B - Reverse folding forming manufacturing method of high-strength plate automobile panel die - Google Patents
Reverse folding forming manufacturing method of high-strength plate automobile panel die Download PDFInfo
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- CN114453519B CN114453519B CN202111617714.3A CN202111617714A CN114453519B CN 114453519 B CN114453519 B CN 114453519B CN 202111617714 A CN202111617714 A CN 202111617714A CN 114453519 B CN114453519 B CN 114453519B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
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Abstract
The invention provides a method for manufacturing a high-strength plate automobile covering part by reverse folding and forming, which comprises the following steps: A. the method comprises the steps of process vertical face and slip analysis, B, defect space subdivision, C, forming circular arc enlargement, C1, feeding circular arc enlargement, C2. arc reference surface circular arc enlargement adjustment, C3. gradual change drawing ribs, D, median wave and debugging reservation, D1, median wave center line determination, D2. median wave width determination, D3, median wave height determination, D4. median wave design, E, hardening prevention and void formation, F, wave shaping, G, programming and numerical control machining, H, grinding and shaping. The invention solves the problem that the rebound distortion caused by the self material property of the high-strength plate and the deformation caused by cold work hardening can not be corrected, shortens the manufacturing period of the high-strength plate automobile covering part mould by more than 30%, can finish the molding of the high-strength plate automobile covering part with the length of 2000mm and the depth of 500mm, provides a convenient channel for the application of the complex high-strength plate automobile covering part, and promotes the development of low cost, high quality, energy conservation and carbon reduction of automobiles.
Description
Technical Field
The invention relates to the technical field of automobile die preparation, in particular to a method for manufacturing a high-strength plate automobile covering part die by reverse folding.
Background
Light weight and energy conservation and emission reduction are important tasks for the development of the automobile industry, the light weight of the automobile can realize great energy conservation, and the light weight and high performance and high safety requirements are pursued for high quality of the automobile. For light weight, the realization is mainly realized by applying high-performance light materials at present, and the main novel materials comprise high-strength plates, aluminum plates, magnesium aluminum alloys and the like. The high-strength plate is continuously better because of low material cost and excellent strength and mechanical properties, and compared with the common automobile plate, the high-strength plate can reduce the weight by 30-60 percent and has huge potential.
However, the high-strength plate is faced with more cold-working forming problems of a die in the forming process, and the biggest influencing factors are that the material has high rebound and serious distortion, and is easy to be cold-worked and hardened in the forming process to form a cold-working arc, so that the quality of the automobile panel is seriously influenced. In addition, the high-strength plate is difficult to correct through a subsequent shaping die after cold working hardening, so that the multiple problems of difficult die manufacturing, long production period, low yield, poor quality and the like are caused, the large-area application of the high-strength plate in the automobile industry is plagued, and the advanced technical barriers are brought to energy conservation, carbon reduction, light weight and high performance of the automobile.
Disclosure of Invention
The invention provides a method for manufacturing a high-strength plate automobile covering part through reverse folding molding, which is applied to photo-thermal conversion, and solves the technical problems of difficult manufacture and low yield of the high-strength plate used as a lightweight automobile.
The technical scheme for realizing the invention is as follows:
a method for manufacturing a high-strength plate automobile panel through reverse folding and forming of a mold comprises the following steps:
A. technological vertical face and sliding analysis: based on a digital molded surface of a product process, process supplementation is performed, CAE analysis is performed, a torsion rebound area and a feeding length are calculated, an area with rebound of more than 0.3mm and feeding distance of more than 5mm is extracted, a geometric center of a stamping direction of the digital molded surface is taken as a center, a maximum trend term of a deep cavity of the digital molded surface is taken as an axial direction, a forming central axis is established, the forming central axis is taken as an axis, and the stamping direction is taken as a reference direction, so that a deep cavity projection surface is established.
B. Defect space subdivision: c, carrying out overall defect space subdivision based on the defect space extracted in the step a, firstly extracting a large-area continuous defect space region accounting for more than 10% of the total area, determining the defect space region as a 1-class region, defining a region with the area more than 5% of the total area and serious rebound distortion of CAE analysis operation as a 2-class region, defining other regions as a 3-class region, establishing a wave reference line for the 1-class region, establishing a wave reference line and adjusting an arc reference surface for the 2-class region, subdividing the 3-class region into two groups, wherein one group is provided with the wave reference line, the other group is provided with a differential region, and carrying out no treatment.
C. Enlarging a forming circular arc; and c, carrying out light smoothing treatment on the areas with large rebound quantity and large slippage quantity in the three areas in the step b, and reducing rebound distortion caused by cold work hardening and rebound distortion caused by uncertain stress of molding by amplifying circular arcs, wherein the method specifically comprises the following operations:
C1. amplifying a feeding circular arc: b, enlarging a feeding circular arc of a process supplementing surface area adjacent to the adjusting circular arc reference surface in the step b;
C2. adjusting arc amplification of an arc reference surface: the arc amplification of the adjusting arc reference surface is only carried out in the area with the subsequent shaping working procedure, and the subsequent area without shaping is not amplified;
C3. gradual change draw bead: and carrying out gradual change treatment on the draw beads in the adjacent area according to the trend and the middle point of the arc reference surface, wherein the gradual change width adjustment quantity is 0.8-1.7 times of the width of the conventional draw beads instead of the conventional equal-width draw beads, so as to solve the problem of increasing inflow quantity of molding materials and the problem that the locking force of the equal-width draw beads cannot be changed according to the feeding condition caused by the fact that the arc of the arc reference surface is adjusted to be amplified.
D. Median wave and debugging reservation: the median wave is to harden the material by cold working in the process of shaping and sliding of the high-strength plate material, and the shaping rebound causes irregular deformation of the molded surface to carry out process correction treatment, and the convex arc is made on the region so as to correct reverse bending of the rebound region in the shaping process, and the treatment mode comprises:
D1. determination of the median wave center line: shifting the wave reference line downwards to the middle position of the lower boundary of the wave reference line and the curved surface, shifting the wave reference line upwards by 15% from the middle position, and carrying out light smoothening and straightening treatment on the shifted curve to obtain a single downward bending curve which approximates to a straight line, wherein the curve is a median wave center line;
D2. width of median wave is determined: the median wave width is different according to the difference of the material thickness, and is approximately selected according to the following formula: median wave width = 3+ (thickness of material 1.5) in mm;
D3. median wave height determination: the median wave height is the protrusion height of the median wave, and the value of the protrusion height is determined according to the thickness and the yield strength of the material;
D4. the design of the median wave, along the median wave center line, the convex waves of the height and the width calculated in the steps D2 and D3 are made on the process digital molded surface, the gradual change combination of 15mm is made at the two ends of the waves, the median wave is used for carrying out reverse folding molding on the high-strength plate in the molding process, and the rebound and irregular deformation problems are corrected, so that a stress surface is formed.
E. Hardening prevention lets out: the middle wave peripheral area performs blank treatment on the male die of the die, so that cold work hardening and sliding lines and accumulated and cut tumors caused by tight fitting drawing are reduced.
F. Wave shaping: and (3) performing side shaping treatment on the automobile covering part with larger rebound distortion, selecting a side shaping mode, manufacturing a plurality of small waves, performing strong shaping on a deformation area through M-shaped continuous reverse bending, and eliminating rebound and distortion in a bending point mode.
G. Programming and numerical control machining: and E, because the hardening prevention is empty and the male die and the female die are inconsistent, different digital dies are selected for programming, and the numerical control machine tool is processed according to a normal high-precision die processing mode.
Further, after the deep cavity projection surface is established in the step A, the included angle between the mark and the stamping direction is smaller than 45 degrees, the curved surface with the projection length larger than 30mm and the trend are coherent, the continuous curved surface with the fluctuation height not exceeding 5mm are projected on the deep cavity projection surface, and the vertical surface and the sliding analysis and the defect space extraction are completed.
Further, the wave reference line and the adjusting arc reference surface in the step B are established by the following modes: for the type 1 region, a connecting line is established by taking the initial region of the maximum rebound region as the center and taking the trend direction of the rebound region as the direction, and the connecting line is used as a wave reference line; marking an arc along the sliding direction by taking the formed arc with the area with the maximum sliding amount as a center, and taking the marked arc as an adjusting arc reference surface; for the class 2 areas, extracting a wave reference line and adjusting an arc reference surface according to a class 1 area mode by selecting an area with a curved surface area larger than 0.2 square meter, and extracting a curved surface rebound molding arc with an area range smaller than the area range as a fairing reference arc; the 3-class area is subdivided into two groups, one group is an area with similar rebound torsion trend in the integral CAE analysis, and a wave reference line is established according to trend.
Further, the feeding circular arc amplification formula in the step C1 is as follows: arc magnification = material thickness reference coefficient x intensity correction coefficient;
the material thickness reference coefficient and the arc reference coefficient are shown in the following table:
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
Further, the amplification in the step C2 adopts a gradual change mode, the amplification is carried out by 1-1.2 times by taking the two ends of the adjusting circular arc as starting points, the amplification of the center of the adjusting circular arc is 1.2 times, and the amplification amount can be freely adjusted by 0.2 times according to CAE deformation analysis and experience conditions.
Further, the median wave height in the step D3 is determined, and according to the scale test, the median wave height is selected and used according to the following categories:
median wave height = material thickness correction high x intensity correction factor;
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
Further, step D5 is included between step D4 and step E: the median wave reference value has the normal property but slightly larger property, if the result correction amount is too large in the molding process of the automobile panel, the median wave height is trimmed and reduced in the debugging process, the molding defect is greatly corrected by micro debugging, and the debugging workload is reduced.
Further, the processing method of the step E comprises the following steps: taking the lower edge of the curved edge as an end point, taking the lower edge of the middle wave as a starting point, carrying out gradual change and blank processing on the male die part of the die in the middle area, carrying out 0-blank gradual change on blank from the starting point to the end point, and keeping the original digital molded surface of the female die unchanged, wherein the blank value is as follows: let null = median wave height 0.4.
Further, the processing method of the step F comprises the following steps: and C, taking the adjusting arc reference surface in the step B as a starting point, upwards shifting by 15mm to form reverse bending waves which are approximately straight lines, wherein the reverse bending waves are first waves for wave shaping, the width and the height of the waves are 30% of those of the median waves, upwards shifting the first waves by 15mm to form second waves, the width and the height of the second waves are 0.9 of those of the first waves, and the like to form third waves and fourth waves … … until the area of 15mm below the median wave reference line is formed, so that wave shaping is completed.
Further, comprises H. Grinding and shaping: after the die processing is completed, the grinding stage is carried out, at this time, grinding is carried out according to a normal mode, and then the qualified purpose of the product is achieved by adjusting the height and width of the median wave and adjusting the width and height of the wave shaping wave.
The beneficial effects of the invention include:
1. according to the invention, craftsmen experience, a novel material CAE technology and batch experiments are combined to form a system high-strength plate automobile covering part mould forming manufacturing technology, and the problems that rebound distortion caused by the material property of the high-strength plate and deformation caused by cold work hardening cannot be corrected are solved by manufacturing waves and letting air, so that the technical difficulty of high-strength plate automobile covering part forming is greatly reduced, the manufacturing period of the high-strength plate automobile covering part mould is shortened by more than 30%, the high-strength plate automobile covering part forming with the length of 2000mm and the depth of 500mm can be completed, a convenient channel is provided for the application of complex high-strength plate automobile covering parts, and the development of low cost, high quality, energy conservation and carbon reduction of automobiles is promoted.
2. The hardening prevention enables the hollow and smooth circular arc manufacture, so that the concentration problem of the forming stress of the high-strength plate material is greatly reduced, the complex automobile panel can be formed, the cold work hardening problem is solved from the forming stage, meanwhile, the problems of torsion, rebound, sliding lines and accumulated scraps are effectively solved, the product is suitable for high-precision requirements, and the yield is over 99 percent.
3. The debugging reservation of the median wave can greatly reduce the technical difficulty and the adjustment period of the lapping debugging, centralize the complicated and unordered debugging area, easily finish the debugging and reduce the debugging test amount by more than 70 percent.
4. The forming mode is provided for the high-strength plate with higher strength, the high-strength plate with the yield strength of more than 500Mpa can be formed by cold stamping through an automobile panel die, a core strength framework is provided for combining the high-strength plate with an aluminum plate and a magnesium aluminum plate, and the combined development of light weight and high performance of the whole automobile is promoted.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of the method of the present invention.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without any inventive effort, are intended to be within the scope of the invention.
The invention aims to solve the problem of forming a high-strength plate automobile covering part die, and solves the problem of irregular deformation caused by cold work hardening of the high-strength plate automobile covering part by carrying out detailed analysis and software simulation on the high-strength plate automobile covering part die, comprehensively analyzing forming know-how of various novel materials, combining with the accumulation of craftsman skills of a large number of products, developing a high-strength plate automobile covering part die reverse folding forming manufacturing technology through repeated experiments, and carrying out decomposition control on the high-strength plate automobile covering part die by establishing a reverse arc and a process bending arc, and carrying out technical means of a deficient cold work hardening area and establishing a process wave side whole surface, thereby solving the problem of irregular deformation caused by cold work hardening of the high-strength plate automobile covering part, effectively solving the problems of distortion, rebound, slip line and built-up bits of the high-strength plate automobile covering part, achieving the high precision, high structural complexity and high performance of the high-strength plate automobile covering part, improving the product quality, reducing the development period of the automobile covering part die, reducing the material waste, and providing powerful support for the wide high-complexity application of the high-strength plate material in the automobile manufacturing.
The invention is based on the experience of craftsmen and the know-how of lightweight materials of a cold stamping die (hereinafter referred to as die) of a large-scale automobile panel; through CAE analysis means and field multiple tests, the problems of rebound, distortion, sliding line, accumulated and cut tumor and poor quality of the high-strength plate cold stamping die are solved, and the high-strength plate automobile panel material thickness interval is 0.5-1.8mm and the yield strength is 220-550Mpa.
Specifically, as shown in fig. 1, a method for manufacturing a high-strength plate automobile panel by reverse folding and forming of a mold comprises the following steps:
A. technological vertical face and sliding analysis: based on a digital molded surface of a product process, process supplementation is performed, CAE analysis is performed, a torsion rebound area and a feeding length are calculated, an area with rebound of more than 0.3mm and feeding distance of more than 5mm is extracted, a geometric center of a stamping direction of the digital molded surface is taken as a center, a maximum trend term of a deep cavity of the digital molded surface is taken as an axial direction, a forming central axis is established, the forming central axis is taken as an axis, and the stamping direction is taken as a reference direction, so that a deep cavity projection surface is established.
After the deep cavity projection surface is established, the included angle between the mark and the stamping direction is smaller than 45 degrees, the curved surface with the projection length larger than 30mm and the trend are coherent, the continuous curved surface with the fluctuation height not exceeding 5mm are projected on the deep cavity projection surface, and the vertical surface and the sliding analysis and the defect space extraction are completed.
B. Defect space subdivision: c, carrying out overall defect space subdivision based on the defect space extracted in the step a, firstly extracting a large-area continuous defect space region accounting for more than 10% of the total area, determining the defect space region as a 1-class region, defining a region with the area more than 5% of the total area and serious rebound distortion of CAE analysis operation as a 2-class region, defining other regions as a 3-class region, establishing a wave reference line for the 1-class region, establishing a wave reference line and adjusting an arc reference surface for the 2-class region, subdividing the 3-class region into two groups, wherein one group is provided with the wave reference line, the other group is provided with a differential region, and carrying out no treatment.
The wave reference line and the adjusting arc reference surface are established by the following modes: for the type 1 region, a connecting line is established by taking the initial region of the maximum rebound region as the center and taking the trend direction of the rebound region as the direction, and the connecting line is used as a wave reference line; marking an arc along the sliding direction by taking the formed arc with the area with the maximum sliding amount as a center, and taking the marked arc as an adjusting arc reference surface; for the class 2 areas, extracting a wave reference line and adjusting an arc reference surface according to a class 1 area mode by selecting an area with a curved surface area larger than 0.2 square meter, and extracting a curved surface rebound molding arc with an area range smaller than the area range as a fairing reference arc; the 3-class area is subdivided into two groups, one group is an area with similar rebound torsion trend in the integral CAE analysis, and a wave reference line is established according to trend.
C. Enlarging a forming circular arc; and c, carrying out light smoothing treatment on the areas with large rebound quantity and large slippage quantity in the three areas in the step b, and reducing rebound distortion caused by cold work hardening and rebound distortion caused by uncertain stress of molding by amplifying circular arcs, wherein the method specifically comprises the following operations:
C1. amplifying a feeding circular arc: b, enlarging a feeding circular arc of a process supplementing surface area adjacent to the adjusting circular arc reference surface in the step b;
the feeding circular arc amplification formula is as follows: arc magnification = material thickness reference coefficient x intensity correction coefficient;
the material thickness reference coefficient and the arc reference coefficient are shown in the following table:
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
C2. Adjusting arc amplification of an arc reference surface: the arc amplification of the adjusting arc reference surface is only carried out in the area with the subsequent shaping working procedure, and the subsequent area without shaping is not amplified; the amplification adopts a gradual change mode, takes the two ends of the adjusting arc as starting points, amplifies by 1-1.2 times, adjusts the center of the arc to amplify by 1.2 times, and freely adjusts the amplification amount by 0.2 times according to CAE deformation analysis and experience conditions.
C3. Gradual change draw bead: and carrying out gradual change treatment on the draw beads in the adjacent area according to the trend and the middle point of the arc reference surface, wherein the gradual change width adjustment quantity is 0.8-1.7 times of the width of the conventional draw beads instead of the conventional equal-width draw beads, so as to solve the problem of increasing inflow quantity of molding materials and the problem that the locking force of the equal-width draw beads cannot be changed according to the feeding condition caused by the fact that the arc of the arc reference surface is adjusted to be amplified.
D. Median wave and debugging reservation: the median wave is to harden the material by cold working in the process of shaping and sliding of the high-strength plate material, and the shaping rebound causes irregular deformation of the molded surface to carry out process correction treatment, and the convex arc is made on the region so as to correct reverse bending of the rebound region in the shaping process, and the treatment mode comprises:
D1. determination of the median wave center line: shifting the wave reference line downwards to the middle position of the lower boundary of the wave reference line and the curved surface, shifting the wave reference line upwards by 15% from the middle position, and carrying out light smoothening and straightening treatment on the shifted curve to obtain a single downward bending curve which approximates to a straight line, wherein the curve is a median wave center line;
D2. width of median wave is determined: the median wave width is different according to the difference of the material thickness, and is approximately selected according to the following formula: median wave width = 3+ (thickness of material 1.5) in mm;
D3. median wave height determination: the median wave height is the protrusion height of the median wave, and the value of the protrusion height is determined according to the thickness and the yield strength of the material; the median wave height is determined, and according to a scale test, the method is selected and used according to the following categories:
median wave height = material thickness correction high x intensity correction factor;
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
D4. The design of the median wave, along the median wave center line, the convex waves of the height and the width calculated in the steps D2 and D3 are made on the process digital molded surface, the gradual change combination of 15mm is made at the two ends of the waves, the median wave is used for carrying out reverse folding molding on the high-strength plate in the molding process, and the rebound and irregular deformation problems are corrected, so that a stress surface is formed.
D5: the median wave reference value has the property of normal but slightly bigger, if the result correction amount is too big in the molding process of the automobile panel, the median wave height can be adjusted and reduced in the debugging process, so that the purpose of correcting the molding defect greatly by micro debugging is achieved, and the debugging workload is greatly reduced.
E. Hardening prevention lets out: the middle wave peripheral area performs blank treatment on the male die of the die, so that cold work hardening and sliding lines and accumulated and cut tumors caused by tight fitting drawing are reduced. The specific treatment method comprises the following steps: taking the lower edge of the curved edge as an end point, taking the lower edge of the middle wave as a starting point, carrying out gradual change and blank processing on the male die part of the die in the middle area, carrying out 0-blank gradual change on blank from the starting point to the end point, and keeping the original digital molded surface of the female die unchanged, wherein the blank value is as follows: let null = median wave height 0.4.
F. Wave shaping: and (3) carrying out side shaping treatment on the automobile covering parts with larger rebound distortion, such as beams, side beams and deep cavity reinforcing plates, selecting a side shaping mode, manufacturing a plurality of small waves, carrying out strong shaping on a deformation area through M-shaped continuous reverse bending, and eliminating rebound and distortion in the form of bending points.
The specific treatment method comprises the following steps: and C, taking the adjusting arc reference surface in the step B as a starting point, upwards shifting by 15mm to form reverse bending waves which are approximately straight lines, wherein the reverse bending waves are first waves for wave shaping, the width and the height of the waves are 30% of those of the median waves, upwards shifting the first waves by 15mm to form second waves, the width and the height of the second waves are 0.9 of those of the first waves, and the like to form third waves and fourth waves … … until the area of 15mm below the median wave reference line is formed, so that wave shaping is completed.
G. Programming and numerical control machining: in the normal mould manufacturing process, the convex-concave mould of the mould is processed by the same number, but the patent has the advantages of hardening prevention, void clearance and inconsistent convex and concave moulds. Because the hardening prevention and void prevention exist in the step E of the embodiment, the male die and the female die are inconsistent, different digital dies are selected for programming, and the numerical control machine tool is processed according to a normal high-precision die processing mode.
H. Grinding and molding: after the die processing is finished, the die enters a grinding and mixing stage, at this time, grinding and mixing are carried out according to a normal mode, and then the qualified purpose of the product is achieved by adjusting the height and the width of the median wave and the width and the height of the wave shaping wave, so that the adjustment is convenient and quick, and the debugging test quantity can be reduced by more than 70%.
The parts of the invention not described or described in detail are conventional technical means for those skilled in the art.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the invention.
Claims (8)
1. A method for manufacturing a high-strength plate automobile panel through reverse folding and forming of a mold is characterized by comprising the following steps:
A. technological vertical face and sliding analysis: taking a digital molded surface of a product process as a basis, performing process supplementation, performing CAE analysis, calculating a torsion rebound area and a feeding length, extracting an area with rebound of more than 0.3mm and a feeding distance of more than 5mm, simultaneously taking the geometric center of the digital molded surface in the stamping direction as the center, taking the longest trend term of a deep cavity of the digital molded surface as the axial direction, establishing a forming central axis, taking the forming central axis as the axis, and taking the stamping direction as the reference direction, and establishing a deep cavity projection surface;
B. defect space subdivision: b, carrying out overall defect space subdivision based on the defect space extracted in the step A, firstly extracting a large-area continuous defect space region accounting for more than 10% of the total area, defining a region with the area more than 5% of the total area and serious rebound distortion of CAE analysis operation as a class-2 region, defining other regions as a class-3 region, establishing a wave reference line for the class-1 region, establishing a wave reference line and adjusting an arc reference surface for the class-2 region, wherein the class-3 region is subdivided into two groups, one group of the wave reference lines is established, the other group of the wave reference lines is a differential region, and the processing is not carried out;
C. enlarging a formed arc: and B, carrying out light smoothing treatment on the areas with large rebound quantity and large slippage quantity in the three areas in the step B, and reducing rebound distortion caused by cold work hardening and rebound distortion caused by uncertain stress of molding by amplifying circular arcs, wherein the method specifically comprises the following operations:
C1. amplifying a feeding circular arc: b, enlarging a feeding circular arc of a process supplementing surface area adjacent to the adjusting circular arc reference surface in the step B;
C2. adjusting arc amplification of an arc reference surface: the arc amplification of the adjusting arc reference surface is only carried out in the area with the subsequent shaping working procedure, and the subsequent area without shaping is not amplified;
C3. gradual change draw bead: gradually changing the draw beads in the adjacent area according to the trend and the middle point of the arc reference surface, wherein the gradually changing width adjustment quantity is 0.8-1.7 times of the width of the conventional draw beads instead of the conventional equal-width draw beads, so that the problems that the inflow quantity of the molding material is increased and the locking force of the equal-width draw beads cannot be changed according to the feeding condition caused by the fact that the arc of the arc reference surface is adjusted after the arc is amplified are solved;
D. median wave and debugging reservation: the median wave is to harden the material by cold working in the process of shaping and sliding of the high-strength plate material, and the shaping rebound causes irregular deformation of the molded surface to carry out process correction treatment, and the convex arc is made on the region so as to correct reverse bending of the rebound region in the shaping process, and the treatment mode comprises:
D1. determination of the median wave center line: shifting the wave reference line downwards to the middle position of the lower boundary of the wave reference line and the curved surface, shifting the wave reference line upwards by 15% from the middle position, and carrying out light smoothening and straightening treatment on the shifted curve to obtain a single downward bending curve which approximates to a straight line, wherein the curve is a median wave center line;
D2. width of median wave is determined: the median wave width is different according to the difference of the material thickness, and is approximately selected according to the following formula: median wave width = 3+ (thickness of material 1.5) in mm;
D3. median wave height determination: the median wave height is the protrusion height of the median wave, and the value of the protrusion height is determined according to the thickness and the yield strength of the material;
D4. the design of the median wave, along the median wave center line, the convex waves of the height and the width calculated in the steps D2 and D3 are made on the process digital molded surface, the gradual change combination of 15mm is made at the two ends of the waves, the median wave is used for carrying out reverse folding molding on the high-strength plate in the molding process, and the rebound and irregular deformation problems are corrected, so that a stress surface is formed;
E. hardening prevention lets out: the middle wave peripheral area performs blank treatment on the male die of the die, so that cold work hardening and sliding lines and accumulated and cut tumors caused by tight fitting drawing are reduced;
F. wave shaping: performing side shaping treatment on the automobile covering part with larger rebound distortion, selecting a side shaping mode, manufacturing a plurality of small waves, performing strong shaping on a deformation area through M-shaped continuous reverse bending, and eliminating rebound and distortion in a bending point mode;
G. programming and numerical control machining: e, because the hardening prevention is empty and the male die and the female die are inconsistent, different digital dies are selected for programming, and the numerical control machine tool is processed according to a normal high-precision die processing mode;
after the deep cavity projection surface is established, the included angle between the mark and the stamping direction is smaller than 45 degrees, the curved surface with the projection length larger than 30mm and the trend are coherent, the continuous curved surface with the fluctuation height not exceeding 5mm are projected on the deep cavity projection surface, and the vertical surface and the sliding analysis and the defect space extraction are completed;
the wave reference line and the adjusting arc reference surface in the step B are established by the following modes: for the type 1 region, a connecting line is established by taking the initial region of the maximum rebound region as the center and taking the trend direction of the rebound region as the direction, and the connecting line is used as a wave reference line; marking an arc along the sliding direction by taking the formed arc with the area with the maximum sliding amount as a center, and taking the marked arc as an adjusting arc reference surface; for the class 2 areas, extracting a wave reference line and adjusting an arc reference surface according to a class 1 area mode by selecting an area with a curved surface area larger than 0.2 square meter, and extracting a curved surface rebound molding arc with an area range smaller than the area range as a fairing reference arc; the 3-class area is subdivided into two groups, one group is an area with similar rebound torsion trend in the integral CAE analysis, and a wave reference line is established according to trend.
2. The method for manufacturing the high-strength panel automobile panel mold by reverse folding according to claim 1, wherein the method comprises the following steps: the feeding circular arc amplification formula in the step C1 is as follows: arc magnification = material thickness reference coefficient x intensity correction coefficient;
the material thickness reference coefficient and the arc reference coefficient are shown in the following table:
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
3. The method for manufacturing the high-strength panel automobile panel mold by reverse folding according to claim 2, wherein the method comprises the steps of: and C2, amplifying in a gradual change mode, namely amplifying by 1-1.2 times by taking the two ends of the adjusting arc as starting points, amplifying by 1.2 times by adjusting the center of the arc, and freely adjusting the amplifying amount by 0.2 times according to CAE deformation analysis and experience conditions.
4. A method for manufacturing a high-strength panel automobile panel by reverse folding and forming according to any one of claims 1 to 3, characterized in that: and D3, determining the median wave height, and selecting and using according to the following categories according to a scale test:
median wave height = material thickness correction high x intensity correction factor;
note that: the boundary value is selected from the upper class column, for example, the material thickness is 0.7mm, and the value corresponding to 0.7-0.9 in class column 2 is selected.
5. The method for manufacturing the high-strength panel automobile panel mold by reverse folding according to claim 4, wherein the method comprises the following steps: the step D5 is included between the step D4 and the step E: the median wave reference value has the normal property but slightly larger property, if the result correction amount is too large in the molding process of the automobile panel, the median wave height is trimmed and reduced in the debugging process, the molding defect is greatly corrected by micro debugging, and the debugging workload is reduced.
6. The method for manufacturing the high-strength panel automobile panel by reverse folding and forming according to any one of claims 1 to 3 and 5, characterized in that: the processing method of the step E comprises the following steps: taking the lower edge of the curved edge as an end point, taking the lower edge of the middle wave as a starting point, carrying out gradual change and blank processing on the male die part of the die in the middle area, carrying out 0-blank gradual change on blank from the starting point to the end point, and keeping the original digital molded surface of the female die unchanged, wherein the blank value is as follows: let null = median wave height 0.4.
7. The method for manufacturing the high-strength panel automobile panel mold by reverse folding according to claim 6, wherein the method comprises the steps of: the processing method of the step F comprises the following steps: and C, taking the adjusting arc reference surface in the step B as a starting point, upwards shifting by 15mm to form reverse bending waves which are approximately straight lines, wherein the reverse bending waves are first waves for wave shaping, the width and the height of the waves are 30% of those of the median waves, upwards shifting the first waves by 15mm to form second waves, the width and the height of the second waves are 0.9 of those of the first waves, and the like to form third waves and fourth waves … … until the area of 15mm below the median wave reference line is formed, so that wave shaping is completed.
8. The method for manufacturing the high-strength panel automobile panel mold reverse folding according to claim 7, wherein: comprises the steps of grinding, mixing and forming: after the mold processing is completed, the grinding stage is entered, at this time, grinding is performed in a normal mode, and then the wave height and width in the middle position are adjusted, and the wave shaping wave width and height are adjusted.
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