WO2021174872A1 - 增加过拉延量的预翻边方法 - Google Patents
增加过拉延量的预翻边方法 Download PDFInfo
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- WO2021174872A1 WO2021174872A1 PCT/CN2020/123284 CN2020123284W WO2021174872A1 WO 2021174872 A1 WO2021174872 A1 WO 2021174872A1 CN 2020123284 W CN2020123284 W CN 2020123284W WO 2021174872 A1 WO2021174872 A1 WO 2021174872A1
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- WIPO (PCT)
- Prior art keywords
- flanging
- arc
- over
- drawn section
- stamping
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Classifications
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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
-
- 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
Definitions
- This application relates to the technical field of stamping and flanging forming, in particular to a pre-flanging method for increasing the amount of over-drawing.
- the sheet material is usually pre-turned directly, and then the pre-turned sheet material is side-turned or edge-wrapped to obtain the final product.
- the product is prone to the following problems: the rebound of the side flanging surface is difficult to control, defects are prone to occur near the flanging corners of the exterior surface of the car body, and the position accuracy of the side flanging surface is poor.
- the rebound of the side flanging surface is difficult to control, defects are prone to occur near the flanging corners of the exterior surface of the car body, and the position accuracy of the side flanging surface is poor.
- the rebound of the side flanging surface is difficult to control
- defects are prone to occur near the flanging corners of the exterior surface of the car body
- the position accuracy of the side flanging surface is poor.
- the main purpose of this application is to propose a pre-flanging method that increases the amount of over-drawing, which aims to solve the problem that the rebound of the side flanging surface in the exemplary technology is difficult to control, and defects are prone to occur near the flanging round corners of the exterior surface of the car body , The position accuracy of the side flanging surface is poor, which seriously affects the quality of the product.
- a pre-flanging method for increasing the amount of over-drawing proposed in this application includes the following steps:
- pre-flanging stamping processing on the sheet material from the end of the over-drawn section to obtain a pre-flanging surface
- the pre-flanged surface is subjected to side flanging or hemming stamping processing to obtain a formed product.
- the sheet material is pre-flanged and stamped from the end of the over-drawn section to obtain a pre-flanged surface; according to the shape of the molded product, the pre-flanged surface is When performing side flanging or edging stamping to obtain a shaped product", the following steps are included:
- a pre-flanged arc is formed by bending between the over-drawn section and the pre-flanging surface
- the pre-flanging surface When the pre-flanging surface is subjected to side flanging or encapsulation stamping to obtain a molded product, the pre-flanging surface forms a side flanging surface or a encapsulating surface, and the exterior surface of the car body and the side flanging Bending between the surfaces or edging surfaces to form a side-flanging arc or edging arc;
- the radius value R of the side-flanging arc or the hemming arc is greater than the radius value R" of the pre-flanging arc.
- the center of the pre-flanging arc and the center of the side-flanging arc or hemming arc are both located on the same side of the pre-flanging surface, and at the same time on the same side of the over-drawn section. side.
- the radius value R of the side flanging arc or the hemming arc is greater than the radius value R" of the pre-flanging arc, and the following relationship is satisfied:
- R" is not more than 0.85R.
- the radius value R of the side flanging arc or the hemming arc is greater than the radius value R" of the pre-flanging arc, which has the following relationship:
- R" is set to 0.8R.
- the sheet material is pre-flanged and stamped from the end of the over-drawn section to obtain a pre-flanged surface; according to the shape of the molded product, the pre-flanged surface is When performing side flanging or edging stamping to obtain a shaped product", the following steps are included:
- the over-drawn section and the pre-flanged surface are bent to form a pre-flanged arc;
- the pre-flanging surface When the pre-flanging surface is subjected to side flanging or encapsulation stamping to obtain a molded product, the pre-flanging surface forms a side flanging surface or a encapsulating surface, and the exterior surface of the car body and the side flanging Bending between the surfaces or edging surfaces to form a side-flanging arc or edging arc;
- the arc length value of the right-angle arc is L
- the sum of the length value of the over-drawn section and the arc length value of the pre-flanging arc is L
- L is equal to L
- the length of the over-drawn section is L 1
- the arc length of the pre-flanging arc is L 2
- the arc angle of the pre-flanging arc is ⁇
- the range of the length value L 1 of the over-drawn section is between 0.15 mm and 0.4 mm.
- the length value L 1 of the over-drawn section has a length value of 0.3 mm.
- the next step is to perform side flanging or hemming stamping on the basis of pre-flanging treatment, so that the over-drawing section can absorb the misalignment of punch fillets caused by processing tolerances and assembly errors in different processes
- the problem is to ensure the position of the side flanging surface, and at the same time, control the plastic deformation and hardening of the fillet during the forward flip to the area outside the exterior surface of the car body, ensuring the quality of the exterior surface of the car body.
- the sheet material is in the process of flanging.
- the plastic deformation is more sufficient, so as to effectively control the springback of the rollover surface.
- the arc length of the right-angled arc formed when the pre-flanging surface is rolled or hemmed is stamped, which is the same as the over-drawn
- the length of the segment and the arc length of the pre-flanging arc are the same in length L", which effectively solves the problem of reverse convexity near the fillet caused by the excessive material during rollover. Further improve product quality.
- Fig. 1 is a schematic flow diagram of the steps of the pre-flanging method for increasing the over-drawing amount provided by this application;
- FIG. 2 is a schematic diagram of the front view structure of the molded product processed by the pre-flanging method for increasing the over-drawing amount in this application;
- Fig. 3 is a schematic cross-sectional view of the S-S section of the molded product described in Fig. 2 (when respectively in the pre-flanging position and the side flanging position).
- the sheet material is usually pre-flanged directly, and then the pre-flanged sheet material is side-turned or stamped to obtain the final product.
- the product is prone to the following problems: the rebound of the side flanging surface is difficult to control, and defects are prone to occur near the flanging round corners of the exterior surface of the car body, which seriously affects the product quality.
- this application provides a pre-flanging method for increasing the amount of over-drawing.
- the pre-flanging method for increasing the amount of overdraw provided by this application includes the following steps:
- the end of the car body appearance surface is also stamped to form an over-drawn section.
- the next process starts from the end of the over-drawn section to pre-flanging the sheet material.
- One process performs side flanging or hemming treatment on the basis of pre-flanging treatment, so that the over-drawing section can absorb the non-overlapping problem of punch fillets caused by processing tolerances and assembly errors in different processes, ensuring rollover
- the position of the side surface; at the same time, the plastic deformation and hardening of the rounded corners during the pre-turning are controlled in the area outside the exterior surface of the car body to ensure the quality of the exterior surface of the car body.
- step S100 that is, "pressing a sheet material to form the exterior surface of the car body, and stamping an over-drawn section on the sheet material along the tangent direction of the end of the exterior surface of the car body"
- S110 First, blank the material according to the requirements of the formed product, and obtain the sheet material to be stamped. Before processing, the shape and size of the molded product have been obtained through the analysis and calculation of the relevant design software, and the size of the sheet can also be obtained through the design software.
- one end of the sheet according to the shape of the A side of the formed product to obtain the appearance of the car body.
- one end of the exterior surface of the car body can be set to a, and the other end can be set to b.
- the length from point a to point b of the exterior surface of the car body can be determined by the design software.
- step S200 that is, "determining the pre-flanging direction according to the shape of the molded product, and the angle of the side flanging or the angle of the wrapping part"
- steps S200 that is, "determining the pre-flanging direction according to the shape of the molded product, and the angle of the side flanging or the angle of the wrapping part"
- the pre-flanging direction can be determined according to the shape of the molded product and the side flanging angle.
- the shape of the molded product and the angle of the side flanging can be determined by pre-design.
- the pre-flanging direction can correspond to the punching direction determined by the product shape, which is convenient for subsequent side-flanging operations.
- the pre-flanging direction can be determined according to the shape of the formed product and the angle of the hemming.
- the shape of the molded product and the angle of the wrapping can also be determined by pre-design.
- the direction of the pre-flanging can correspond to the direction of the hemming, which is convenient for the subsequent operation of the hemming.
- step S100 and step S200 do not have a sequence.
- the two steps can be performed at the same time, or any one of step S100 and step S200 can be performed first.
- step S300 that is, "according to the determined pre-flanging direction, perform pre-flanging stamping processing on the sheet material from the end of the over-drawn section to obtain a pre-flanging surface"
- steps may be included:
- the starting point of the pre-flanging treatment can be located at the end of the over-drawn section instead of the end of the exterior surface of the car body, which can reduce the deformation of the exterior surface of the car body.
- the sheet material is pre-flanged and stamped from the end of the over-drawn section, and a straight pre-flanged surface is formed at the end of the sheet, which is convenient for subsequent subsequent stamping of the pre-flanged surface.
- the pre-flanging arc is formed by bending between the over-drawn section and the pre-flanging surface. That is, when the end of the sheet is punched according to the pre-flanging direction, the position between the over-drawn section and the pre-flanging surface will be bent, thereby forming a pre-flanging arc connecting the two.
- the starting point of the pre-flanging arc can be set as the end point c" of the over-drawn section, and the end point of the pre-flanging arc can be set as the d" point; the starting point of the pre-flanging surface can also be set as the pre-flanging
- the end point d" of the arc, set the end point of the pre-flanging surface to e" and the pre-flanging surface can be made straight and tangent to the pre-flanging arc, where d" is the tangent point.
- step S400 that is, "according to the shape of the molded product, the pre-flanged surface is subjected to side flanging or hemming stamping to obtain a molded product"
- steps S400 that is, "according to the shape of the molded product, the pre-flanged surface is subjected to side flanging or hemming stamping to obtain a molded product"
- a side-flanging surface is formed on the pre-flanging surface, and a curved surface is formed between the exterior surface of the vehicle body and the side-flanging surface. Side flanging arc.
- the pre-flanging surface is formed as a hemming surface, and a hemming circle is formed between the exterior surface of the car body and the hemming surface. arc.
- the situation where the formed product is obtained by the hemming stamping process is basically the same as the situation where the formed product is obtained by the side flanging stamping process. This embodiment mainly describes the situation where the side flanging stamping process obtains the formed product.
- step S410 "when the pre-flanged surface is subjected to a side flanging stamping process to obtain a molded product, a side flanging surface is formed on the pre-flanged surface, and the exterior surface of the vehicle body is similar to the side flanging surface.
- the following steps are included:
- the exterior surface of the car body is positioned, and the pre-flanging surface is subjected to side flanging stamping from the starting point of the over-drawn section;
- the pre-flanging surface Press the pre-flanging surface to the forming position of the molded product, forming a side flanging surface on the pre-flanging surface, and forming a continuous side flanging arc between the exterior surface of the car body and the side flanging surface.
- the two ends of the flanging arc are respectively connected to the end point of the exterior surface of the car body and the starting point of the side flanging surface.
- the starting point of the side flanging arc can be tangent to the end point of the exterior surface of the car body, and the end point of the side flanging arc can be tangent to the starting point of the side flanging surface, so that the various parts of the final formed product can be connected smoothly. .
- the starting point of the side flanging arc can be set as the end point b of the exterior surface of the car body, the end point of the side flanging arc can be set as c, and the end point c of the side flanging arc can be the starting point of the side flanging surface.
- the radius of the side-flanging arc can be set to R, and the center of the side-flanging arc is O; the radius of the pre-flanging arc can be set to R", and the center of the pre-flanging arc is O".
- the center O" of the pre-flanging arc and the center O of the side-flanging arc are both located on the same side of the pre-flanging surface, and at the same time on the same side of the over-drawn section.
- the pre-flanging direction and the side flanging direction are the same, and the center O" of the pre-flanging arc is located inside the fan-shaped area formed by the side flanging arc and its center O.
- the radius value R of the side flanging arc is greater than the radius value R" of the pre-flanging arc.
- R" the radius value of the pre-flanging arc.
- the sheet material Since the radius value R" of the pre-flanging arc is smaller than the radius value R of the side-flanging arc or the hemming arc, the sheet material is in the process of flanging, The plastic deformation is more sufficient, thereby effectively controlling the springback of the rollover surface.
- the flanging direction accuracy cannot be guaranteed due to manufacturing errors in the exemplary technology and the appearance of the car body surface and the side flanging arc is avoided.
- "Double eyelid" defect Exemplary technology is directly bent between the pre-flanging surface and the exterior surface of the car body to form a side flanging fillet, and there is no over-drawn section bc". Due to processing tolerances or assembly errors, the pre-flanging punch and The point b of the two processes on the side flanging punch cannot be completely overlapped, which affects the position accuracy of the side flanging surface.
- the b point position during the forward flip has undergone plastic deformation and hardening. If the b point of the two processes does not overlap, the previous The parts that have been hardened during the process may remain on the exterior surface of the car body, causing "double eyelids" defects.
- the over-drawn section bc" is added to absorb the above tolerances and errors, and the defects can be controlled on the surface of the non-car body (such as the side flanging arc or the side flanging surface).
- radius value R of the side-flanging arc is greater than the radius value R" of the pre-flanging arc and satisfies the following relationship:
- R" is not more than 0.85R.
- the radius value R of the side flanging arc By controlling the radius value R of the side flanging arc to be greater than or equal to 1.18 times the radius value R" of the pre-flanging arc, the springback of the side flanging surface can be better reduced. Moreover, in this embodiment , the radius value R of the side-flanging arc can be made greater than the radius value R" of the pre-flanging arc, which has the following relationship:
- R" is set to 0.8R.
- steps S300 and S400 “according to the determined pre-flanging direction, perform pre-flanging stamping processing on the sheet material from the end of the over-drawn section to obtain a pre-flanging surface;
- the pre-flanging surface is processed by side flanging or hemming stamping to obtain a molded product
- the following steps are included:
- a pre-flanged arc is formed by bending between the over-drawn section and the pre-flanging surface
- the pre-flanging surface When the pre-flanging surface is subjected to side flanging or encapsulation stamping to obtain a molded product, the pre-flanging surface forms a side flanging surface or a encapsulating surface, and the exterior surface of the car body and the side flanging The sides or edging surfaces are curved to form a side-flanging arc. From the above content, it can be seen that the vehicle body exterior surface ab and the side flanging surface cd are curved to form a side flanging arc bc.
- L is at least L and not more than 1.03L.
- the final formed product will not be due to side flanging
- the above-mentioned side flanging arc (or hemming arc) can also include a transition arc ec, connect the right-angle arc be and the side flanging surface cd (or edging surface).
- the arc length value of the right-angled arc be is L
- the sum of the length value of the over-drawn section bc" and the arc length value of the pre-flanging arc c"d" is L
- L is equal to L
- the arc length value of the right-angled arc be and the length value of the over-drawn section bc" and the pre-flanging arc c"d "The sum of the arc length values is the same, which can achieve a better effect of preventing the adverse convexity.
- the arc length of the right-angled arc formed when the pre-flanging surface is side-flanged or hemmed stamped is L, which is between the length of the over-drawn section and the arc length of the pre-flanged arc It is the same length as L", which effectively solves the problem of reverse convexity near the rounded corners caused by the excessive material during the rollover, which can further improve the product quality.
- the length of the over-drawn section can be set to L 1
- the arc length of the pre-flanging arc is L 2
- the arc angle of the pre-flanging arc is ⁇
- the range of the length value L 1 of the over-drawn section can be made 0.15-0.4 mm. At this time, better effects of anti-rebound, anti-double eyelid defect and anti-reverse convexity can be achieved.
- the length value L 1 of the over-drawn section can be made to have a length value of 0.3 mm. In this case, relatively better anti-rebound, anti-double eyelid defects and anti-convex effects can be achieved.
- the length value of the length value L 1 of the over-drawn section may also be set to 0.15 mm or 0.4 mm, or may be set to other length values between 0.15 mm and 0.4 mm.
- the present application can also propose a pre-flanging die surface structure with increased over-drawing amount manufactured according to the above-mentioned pre-flanging method for increasing over-drawing amount.
- the amount of springback generated by the side flanging in the subsequent process can be reduced, and the springback of the side flanging surface cd can be effectively controlled; the accuracy of the side flanging surface of the part can be guaranteed; the appearance of the car body "double eyelid" defect can be avoided,
- the defect probability is reduced to 0%, and the repair rate is reduced to 0%; the side-flanging arc (that is, the R angle) does not produce reverse convexity near point b, and the defect probability is reduced to 0%; the quality of parts is improved, and the product and adjacent products Clearance and surface aberration, reduce the repair rate, shorten the mold manufacturing cycle, and reduce the manufacturing cost.
Abstract
一种增加过拉延量的预翻边方法，包括如下步骤：在板料上冲压形成车体外观面，沿所述车体外观面末端切线方向在所述板料上冲压形成过拉延段；根据成型产品形状、侧翻边角度或者包边放件角度，确定预翻边方向；根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品。该方法解决了侧翻边面的回弹难以控制，车体外观面的翻边圆角附近容易出现缺陷，侧翻边面位置精度差，严重影响产品质量的问题。
Description
相关申请
本申请要求于2020年05月26日提交中国专利局、申请号为202010457863.7、发明名称为“增加过拉延量的预翻边方法”的中国专利申请的优先权，其全部内容通过引用结合在申请中。
本申请涉及冲压翻边成型技术领域，具体涉及一种增加过拉延量的预翻边方法。
随着汽车行业的飞速发展，客户对汽车外观质量要求愈加严格，提高车体外观面的质量显得尤为重要。针对类似发动机罩外板、车门外板、后背门外板、行李箱外板类的需要包边的产品和顶盖外板类需要侧整形的产品，即中间工序为预翻边工序的产品，示例性技术中通常直接对板料进行预翻，然后对预翻后的板料进行侧翻或者包边成型，以得到最终产品。而采用这种示例性技术的预翻工艺，产品容易出现如下问题：侧翻边面的回弹难以控制，车体外观面的翻边圆角附近容易出现缺陷，侧翻边面位置精度差，严重影响产品质量。
本申请的主要目的是提出一种增加过拉延量的预翻边方法，旨在解决示例性技术中侧翻边面的回弹难以控制，车体外观面的翻边圆角附近容易出现缺陷，侧翻边面位置精度差，严重影响产品质量的问题。
为实现上述目的，本申请提出的一种增加过拉延量的预翻边方法，包括如下步骤：
在板料上冲压形成车体外观面，沿所述车体外观面末端切线方向在所述板料上冲压形成过拉延段；
根据成型产品形状、以及侧翻边角度或者包边放件角度，确定预翻边方向；
根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；
根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品。
可选地，在“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品”时，包括如下步骤：
从所述过拉延段末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧；
对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面或者包边面，所述车体外观面与所述侧翻边面或者包边面之间弯曲形成侧翻边圆弧或者包边圆弧；
其中，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"。
可选地，所述预翻边圆弧的圆心和所述侧翻边圆弧或者包边圆弧的圆心均位于所述预翻边面的同侧，同时位于所述过拉延段的同侧。
可选地，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"满足如下关系：
R"不大于0.85R。
可选地，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"具有如下关系：
R"设置为0.8R。
可选地，在“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品”时，包括如下步骤：
从所述过拉延段的末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧；
对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面或者包边面，所述车体外观面与所述侧翻边面或者包边面之间弯曲形成侧翻边圆弧或者包边圆弧；
其中，假设以所述侧翻边圆弧或者包边圆弧的圆心为圆心、以所述过拉延段的起始端端点为起点、在所述侧翻边圆弧或者所述包边圆弧上取一段直角圆弧，并使得所述直角圆弧的圆弧长度值为L，所述过拉延段的长度值和所述预翻边圆弧的圆弧长度值之和为L"，则满足如下关系：L"至少为L且不超过1.03L。
可选地，所述直角圆弧的圆弧长度值为L，所述过拉延段的长度值和所述预翻边圆弧的圆弧长度值之和为L"，且具有如下关系：L等于L"。
可选地，所述过拉延段的长度值为L
1，所述预翻边圆弧的圆弧长度值为L
2，所述预翻边圆弧的圆弧角度值为θ，且具有如下关系：
L
1=
L"-L
2=（1~1.03）*1/4*2π*R-θ*R"。
可选地，所述过拉延段的长度值L
1的范围为0.15mm到0.4mm之间。
可选地，所述过拉延段的长度值L
1的长度值为0.3mm。
本申请提供的技术方案中，在板料上冲压形成车体外观面时，还在车体外观面末端冲压形成过拉延段，下一工序从过拉延段末端开始对板料进行预翻边处理，下一工序在预翻边处理的基础上进行侧翻边或者包边冲压处理，这样可以通过过拉延段吸收不同工序中由于加工公差和装配误差造成的凸模圆角的不重合问题，确保了侧翻边面的位置度，同时，将正翻时圆角的塑性变形和硬化控制在车体外观面外的区域，保证了车体外观面的质量。而且，通过设置过拉延段后进行预翻边处理，由于预翻边圆弧的半径值R"小于侧翻边圆弧或者包边圆弧的半径值R，板料在翻边过程中，塑性变形更充分，从而有效的控制侧翻面的回弹。另外，对预翻边面进行侧翻边或者包边冲压处理时形成的直角圆弧的圆弧长度值为L，与过拉延段的长度值和预翻边圆弧的圆弧长度值之和L"，二者长度相当，有效解决侧翻时由于多料而被翻边刀块带起圆角附近反凸的不良，可进一步地提升产品质量。
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图示出的结构获得其他的附图。
图1为本申请提供的增加过拉延量的预翻边方法的步骤流程示意图；
图2为本申请采用所述增加过拉延量的预翻边方法加工的成型产品的前视结构示意简图；
图3为图2中所述成型产品的S-S截面（分别处于预翻边位置和侧翻边位置时）的截面示意图。
本申请目的的实现、功能特点及优点将结合实施例，参照附图做进一步说明。
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请的一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
需要说明，若本申请实施例中有涉及方向性指示（诸如上、下、左、右、前、后……），则该方向性指示仅用于解释在某一特定姿态（如附图所示）下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。
另外，若本申请实施例中有涉及“第一”、“第二”等的描述，则该“第一”、“第二”等的描述仅用于描述目的，而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外，全文中出现的“和/或”的含义，包括三个并列的方案，以“A和/或B”为例，包括A方案、或B方案、或A和B同时满足的方案。另外，各个实施例之间的技术方案可以相互结合，但是必须是以本领域普通技术人员能够实现为基础，当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在，也不在本申请要求的保护范围之内。
随着汽车行业的飞速发展，客户对汽车外观质量要求愈加严格，提高车体外观面的质量显得尤为重要。针对类似发动机罩外板、车门外板、后背门外板、行李箱外板类的需要包边的产品和顶盖外板类需要侧整形的产品，即中间工序为预翻边工序的产品，示例性技术中通常直接对板料进行预翻边，然后对预翻边后的板料进行侧翻成型或者包边冲压，以得到最终产品。而采用这种示例性技术的翻边工艺，产品容易出现如下问题：侧翻边面的回弹难以控制，车体外观面的翻边圆角附近容易出现缺陷，严重影响产品质量。
鉴于上述，本申请提供了一种增加过拉延量的预翻边方法。
请参阅图1，本申请提供的一种增加过拉延量的预翻边方法，包括如下步骤：
S100、在板料上冲压形成车体外观面，沿所述车体外观面末端切线方向在所述板料上冲压形成过拉延段；
S200、根据成型产品形状、以及侧翻边角度或者包边放件角度，确定预翻边方向；
S300、根据确定的预翻边方向，从所述过拉延段的末端对板料进行预翻边冲压处理，获得预翻边面；
S400、根据成型产品形状，对所述预翻边面进行侧翻边或包边冲压处理得到成型产品（如图2所示，本申请以顶盖外板为例进行说明。但是，需要指出的是，本申请除了应用于顶盖外板之外，还可针对类似发动机罩外板、车门外板、后背门外板、行李箱外板类的需要包边的产品和顶盖外板类需要侧整形的产品，即中间工序为正翻（预翻）工序的产品）。
这样，在板料上冲压形成车体外观面时，还在车体外观面的末端冲压形成过拉延段，下一工序从过拉延段的末端开始对板料进行预翻边处理，下一工序在预翻边处理的基础上进行侧翻边或者包边处理，这样可以通过过拉延段吸收不同工序由于加工公差和装配误差造成的凸模圆角的不重合问题，确保了侧翻边面的位置度；同时，将预翻时圆角的塑性变形和硬化控制在车体外观面外的区域，保证了车体外观面的质量。
具体地，在上述步骤S100，即“在板料上冲压形成车体外观面，沿所述车体外观面末端切线方向在所述板料上冲压形成过拉延段”时，可包括如下步骤：
S110、先根据成型产品需求进行落料，获取待冲压的板料。在进行加工之前，已经通过相关的设计软件分析计算获取了成型产品的形状尺寸，板料的尺寸也可经过设计软件获取。
S120、根据成型产品的A面形状，对板料的一端进行冲压，获得车体外观面。如图3所示，车体外观面的一端可设为a，另一端可设为b，车体外观面的a点到b点的长度可经过设计软件确定。
S130、在车体外观面的末端，冲压形成一段直线的过拉延段，使得过拉延段处于车体外观面的末端切线方向。可使得过拉延段与车体外观面的切点为b点，而过拉延段的终点可设为c"点。
此外，需要指出的是，在上述步骤S120和步骤S130中，车体外观面和过拉延段可在同一工序中成型，二者并不具有先后顺序。
而且，在上述步骤S200，即“根据成型产品形状、以及侧翻边角度或者包边放件角度，确定预翻边方向”时，可包括如下步骤：
S210、对于需要侧翻边处理的产品，可根据成型产品形状及侧翻边角度，确定预翻边方向。成型产品形状及侧翻边角度，均可通过预先的设计确定。而预翻边方向可与产品形状确定的冲压方向对应，便于后续进行侧翻边操作。
S220、对于需要包边处理的产品，可根据成型产品形状及包边放件角度，确定预翻边方向。成型产品形状及包边放件角度，也均可通过预先的设计确定。而预翻边方向可与包边放件的方向对应，便于后续进行包边放件操作。
此外，也需要指出的是，上述步骤S100和步骤S200，二者也不具有先后顺序，两个步骤可同时进行，也可使步骤S100和步骤S200中任意一个步骤先进行。
此外，在上述步骤S300，即“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面”时，可包括如下步骤：
根据确定的预翻边方向，对所述过拉延段进行定位。这样，可使得进行预翻边处理的起点位于过拉延段的末端，而非车体外观面的末端，可以减少车体外观面的变形。
从所述过拉延段的末端对板料进行预翻边冲压处理，在板料的末端形成平直的预翻边面，便于后续继续对预翻边面进行冲压。
而且，从所述过拉延段末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧。即在按照预翻边方向对板料的末端进行冲压时，过拉延段与预翻边面之间的位置处会产生弯曲，从而形成了连接二者的预翻边圆弧。而且，可设置预翻边圆弧的起始点为过拉延段的终点c"点，设置预翻边圆弧的终点为d"点；还可设置预翻边面的起始点为预翻边圆弧的终点d"点，设置预翻边面的终点为e"，而且可使得预翻边面为平直面，并与预翻边圆弧相切，其中d"点为切点。
而且，在步骤S400，即“根据成型产品形状，对所述预翻边面进行侧翻边或包边冲压处理得到成型产品”时，包括如下步骤：
S410、对所述预翻边面进行侧翻边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面，所述车体外观面与所述侧翻边面之间弯曲形成侧翻边圆弧。
S420、对所述预翻边面进行包边冲压处理得到成型产品时，所述预翻边面形成为包边面，所述车体外观面与所述包边面之间弯曲形成包边圆弧。包边冲压处理得到成型产品的情况与侧翻边冲压处理得到成型产品的情况基本相同，本实施例主要以侧翻边冲压处理得到成型产品的情况进行描述。
进一步地，在步骤S410，“对所述预翻边面进行侧翻边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面，所述车体外观面与所述侧翻边面之间弯曲形成侧翻边圆弧”时，包括如下步骤：
以成型产品的形状及侧翻边角度，对车体外观面进行定位，并从过拉延段的起始点位置对预翻边面进行侧翻边冲压处理；
冲压预翻边面到成型产品的成型位置处，在所述预翻边面上形成侧翻边面，并在车体外观面和侧翻边面之间形成连续的侧翻边圆弧，侧翻边圆弧两端分别连接车体外观面的终点和侧翻边面的起点。而且，侧翻边圆弧的起点可与车体外观面的终点相切，侧翻边圆弧的终点可与侧翻边面的起点相切，这样使得最终获得的成型产品各个部位连接顺滑。
此外，可设置侧翻边圆弧的起点为车体外观面的终点b，可设置侧翻边圆弧的终点为c，同时侧翻边圆弧的终点c为侧翻边面的起点，可设置侧翻边面的终点为d。而且，还可设置侧翻边圆弧的半径值为R，侧翻边圆弧的圆心为O；可设置所述预翻边圆弧的半径值为R"，预翻边圆弧的圆心为O"。
而且，所述预翻边圆弧的圆心O"和所述侧翻边圆弧的圆心O均位于所述预翻边面的同侧，同时位于所述过拉延段的同侧。这样，使得预翻边方向和侧翻边方向相同，而且使得预翻边圆弧的圆心O"位于侧翻边圆弧与其圆心O围设形成的扇形区域内侧。
其中，所述侧翻边圆弧的半径值R大于所述预翻边圆弧的半径值R"。通过使得R"小于R，从而在进行预翻边操作时，可使预翻边圆弧处充分发生塑性变形，并产生硬化，减小了后续进行侧翻边操作时侧翻边面所产生的回弹量，可以更好地达到控制侧翻边面回弹的目的。这样，通过设置过拉延段后进行预翻边处理，由于预翻边圆弧的半径值R"小于侧翻边圆弧或者包边圆弧的半径值R，板料在翻边过程中，塑性变形更充分，从而有效的控制侧翻面的回弹。
而且，通过增加过拉延段bc"，并进行上述的操作及设置，避免了示例性技术由于制造误差而产生的翻边方向精度无法保证和车体外观面与侧翻边圆弧附近出现“双眼皮”缺陷。示例性技术预翻边面和车体外观面之间直接弯曲形成侧翻边圆角，不存在过拉延段bc"，由于加工公差或者装配误差，预翻边凸模和侧翻边凸模上两工序b点无法完全重合，从而影响侧翻边面位置精度，同时，正翻时的b点位置已经发生塑性变形和硬化，如果两工序的b点不重合，则前工序已经硬化的部位有可能会留在车体外观面上，出现“双眼皮”缺陷。而本技术方案通过增加过拉延段bc"，用以吸收上述公差和误差，可将缺陷控制在非车体外观面上（如侧翻边圆弧或侧翻边面）。
进一步地，所述侧翻边圆弧的半径值R大于所述预翻边圆弧的半径值R"满足如下关系：
R"不大于0.85R。
通过控制使得侧翻边圆弧的半径值R大于等于预翻边圆弧的半径值R"的1.18倍，可以更好地减小侧翻边面的回弹量。而且，在本实施例中，可使得所述侧翻边圆弧的半径值R大于所述预翻边圆弧的半径值R"具有如下关系：
R"设置为0.8R。
此时可达到更好的效果。此外，也可使得R"=0.7R，或者R"=0.6R，等等。
此外，在上述步骤S300和S400，即“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品”时，包括如下步骤：
从所述过拉延段末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧；
对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面或者包边面，所述车体外观面与所述侧翻边面或者包边面之间弯曲形成侧翻边圆弧。由上述内容可知，所述车体外观面ab与所述侧翻边面cd之间弯曲形成侧翻边圆弧bc。
其中，假设以侧翻边圆弧或者包边圆弧的圆心O为圆心、以所述过拉延段的起始端端点b为起点、在所述侧翻边圆弧或者所述包边圆弧上取一段直角圆弧，并使得所述直角圆弧的终点为e（即直角圆弧be所对应的圆弧角为90°），而且可设置所述直角圆弧be的圆弧长度值为L，所述过拉延段bc"的长度值和所述预翻边圆弧c"d"的圆弧长度值之和为L"，则满足如下关系：
L"至少为L且不超过1.03L。
这样，通过对直角圆弧be的圆弧长度、以及过拉延段bc"的长度和预翻边圆弧c"d"的圆弧长度进行定义，使得最终成型产品不会由于在侧翻边时多料而被翻边刀块带起，而使得侧翻边圆弧在b点附近产生反凸的不良。此外，上述侧翻边圆弧（或者包边圆弧）还可包括过渡圆弧ec，将直角圆弧be和侧翻边面cd（或包边面）二者连接起来。
进一步地，在所述直角圆弧be的圆弧长度值为L，所述过拉延段bc"的长度值和所述预翻边圆弧c"d"的圆弧长度值之和为L"时，可具有如下关系：L等于L"。此时，所述直角圆弧be的圆弧长度值与所述过拉延段bc"的长度值和所述预翻边圆弧c"d"的圆弧长度值之和相同，可以取得更好的防止出现反凸不良效果。即，对预翻边面进行侧翻边或者包边冲压处理时形成的直角圆弧的圆弧长度值为L，与过拉延段的长度值和预翻边圆弧的圆弧长度值之和L"，二者长度相当，有效解决侧翻时由于多料而被翻边刀块带起圆角附近反凸的不良，可进一步地提升产品质量。
而且，可设置所述过拉延段的长度值为L
1，所述预翻边圆弧的圆弧长度值为L
2，所述预翻边圆弧的圆弧角度值为θ，且具有如下关系：
L
1=
L"-L
2=（1~1.03）*1/4*2π*R-θ*R"。
这样，通过对过拉延段的长度及预翻边圆弧的圆弧长度的进一步定义，可以取得更好的防反凸效果。
进一步地，可使得所述过拉延段的长度值L
1的范围为0.15~0.4mm。此时，可取得更好的防回弹、防双眼皮缺陷及防反凸效果。更进一步地，可使得所述过拉延段的长度值L
1的长度值为0.3mm，此时可取得相对更好的防回弹、防双眼皮缺陷及防反凸效果。此外，也可将过拉延段的长度值L
1的长度值设为0.15mm、或0.4mm，也可设置为0.15mm到0.4mm之间的其他长度值。
此外，本申请还可提出根据上述增加过拉延量的预翻边方法制作出来的一种增加过拉延量的预翻边模面结构。这样，可减小了后工序侧翻边所产生的回弹量，有效控制侧翻边面cd的回弹；保证零件侧翻边面精度；避免车体外观面“双眼皮”缺陷的产生，缺陷概率降低至0%，返修率降低至0%；侧翻边圆弧（即R角）在b点附近不产生反凸，缺陷概率降低至0%；提升零件质量，产品与相邻产品的间隙面差，降低返修率，缩短模具制造周期，降低制造成本。
以上所述仅为本申请的可选实施例，并非因此限制本申请的专利范围，凡是在本申请的实用新型构思下，利用本申请说明书及附图内容所作的等效结构变换，或直接/间接运用在其他相关的技术领域均包括在本申请的专利保护范围内。
Claims (10)
- 一种增加过拉延量的预翻边方法，其中，包括如下步骤：在板料上冲压形成车体外观面，沿所述车体外观面末端切线方向在所述板料上冲压形成过拉延段；根据成型产品形状、以及侧翻边角度或者包边放件角度，确定预翻边方向；根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；以及，根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品。
- 根据权利要求1所述的增加过拉延量的预翻边方法，其中，在“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品”时，包括如下步骤：从所述过拉延段的末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧；以及，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面或者包边面，所述车体外观面与所述侧翻边面或者包边面之间弯曲形成侧翻边圆弧；其中，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"。
- 根据权利要求2所述的增加过拉延量的预翻边方法，其中，所述预翻边圆弧的圆心和所述侧翻边圆弧或包边圆弧的圆心均位于所述预翻边面的同侧，同时位于所述过拉延段的同侧。
- 根据权利要求2所述的增加过拉延量的预翻边方法，其中，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"满足如下关系：R"不大于0.85R。
- 根据权利要求4所述的增加过拉延量的预翻边方法，其特征在于，所述侧翻边圆弧或者包边圆弧的半径值R大于所述预翻边圆弧的半径值R"具有如下关系：R"设置为0.8R。
- 根据权利要求1所述的增加过拉延量的预翻边方法，其中，在“根据确定的预翻边方向，从所述过拉延段末端对板料进行预翻边冲压处理，获得预翻边面；根据成型产品形状，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品”时，包括如下步骤：从所述过拉延段的末端对板料进行预翻边冲压处理获得预翻边面时，所述过拉延段与所述预翻边面之间弯曲形成预翻边圆弧；以及，对所述预翻边面进行侧翻边或者包边冲压处理得到成型产品时，所述预翻边面上形成侧翻边面或者包边面，所述车体外观面与所述侧翻边面或者包边面之间弯曲形成侧翻边圆弧或者包边圆弧；其中，假设以所述侧翻边圆弧或者包边圆弧的圆心为圆心、以所述过拉延段的起始端端点为起点、在所述侧翻边圆弧或者所述包边圆弧上取一段直角圆弧，并使得所述直角圆弧的圆弧长度值为L，所述过拉延段的长度值和所述预翻边圆弧的圆弧长度值之和为L"，则满足如下关系：L"至少为L且不超过1.03L。
- 根据权利要求6所述的增加过拉延量的预翻边方法，其中，所述直角圆弧的圆弧长度值为L，所述过拉延段的长度值和所述预翻边圆弧的圆弧长度值之和为L"，且具有如下关系：L等于L"。
- 根据权利要求6所述的增加过拉延量的预翻边方法，其中，所述过拉延段的长度值为L 1，所述预翻边圆弧的圆弧长度值为L 2，所述预翻边圆弧的圆弧角度值为θ，且具有如下关系：L 1= L"-L 2=（1~1.03）*1/4*2π*R-θ*R"。
- 根据权利要求8所述的增加过拉延量的预翻边方法，其中，所述过拉延段的长度值L 1的范围为0.15mm到0.4mm之间。
- 根据权利要求9所述的增加过拉延量的预翻边方法，其中，所述过拉延段的长度值L 1的长度值为0.3mm。
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