B180H1天窗顶盖修边碎屑的解决措施

目的 采用五工序成形工艺生产天窗顶盖,中间及尾部R角和曲线造型修边工艺设计在OP20和OP40工序,研究此两序下天窗顶盖的修边刃口,改善零件的切边碎屑.方法 利用B180H1材质设计一种天窗冲压修边工艺及模具,建立天窗顶盖成形工艺,在生产过程中,通过调整刃口间隙、垂直度、符型、刃入量等改善修边碎屑.结果 在设计的OP20和OP40工序工艺中,修边刃口符型,两侧激光焊直边采用镶块而非整体结构,刃入量和刃口间隙分别为6 mm和0.035 mm,采用二级废料刀结构有效改善了修边碎屑.结论 天窗顶盖修边工艺排布在OP20和OP40工艺合理,修边碎屑和上下模修边刃口间隙、刃入量、废料刀相关,研配模具可以有效改善碎屑压伤,提升产品质量和实际生产效率.     

高档餐盒复合模设计

通过对餐盒零件的分析,确定了零件冲压成形的工艺方案,设计了一副高精度的复合模,解决了在冲压过程中零件材料薄易起皱等问题.论述了模具的结构设计及工作过程,模具采用气压装置提供压边力,提高了毛坯的成形性能,并设计了新型卷边工艺,提高了零件的成品率,实现了该零件生产的顺利进行.     

某车型后防撞梁热冲压工艺研究

目的研究复杂热成形零件——后防撞梁的热冲压成形工艺。方法通过计算机成形仿真分析防撞梁的成形性,并获得零件的减薄率分布;利用根据仿真过程设计的热成形模具进行防撞梁零件热冲压生产,对实际成形后的零件割样进行性能检测,包括拉伸性能测试、金相组织测试和硬度测试,验证零件的性能。结果利用该工艺生产的零件尺寸稳定且性能良好,最大减薄率为14.9%,最大增厚9.7%;断后伸长率≥5%,镀层厚度为30～50μm,芯部组织为完全马氏体,硬度大于HV400。结论仿真技术能够指导热冲压工艺设计和模具设计,为复杂零件的热冲压工艺及模具设计提供参考。     

深孔筒套精密成形工艺及模具设计

目的对深孔筒套精密件成形过程与难度进行分析,确定其工艺方案,设计出合适的成形模具,并保证零件尺寸精度。方法通过结合UG与CAD软件,制定零件成形工艺方案,绘制零件成形模具图。结果该零件须通过三套成形模具进行冷挤压成形,包括一次复合挤压和两次正挤压。结论该零件的成形模具能保证深孔筒套零件的成形精度并使其较好成形。     

轴承盖冲压工艺分析及模具设计

通过对轴承盖零件冲压成形工艺进行了分析,介绍了零件的工艺参数的计算及设备的选择,同时介绍了模具结构及模具的工作过程,分析了零件引伸过程中产生拉裂现象的原因,并给出了解决措施,实现了该零件引伸的顺利进行,得出了垫旧报纸可以解决零件拉裂现象的方法。     

飞行器支撑零件的冲压模具设计

模具在飞行器零件制造中有很重要的地位,同时它也被评为百业之母,说明飞行器零件都可以通过模具进行加工,在飞行器零件中有种支撑零件,它的加工方法是通过冲压成形的,本文通过飞行器零件工艺分析,对凸凹模设计,最后进行模具设计,实现对零件的加工。     

面板剪切弯曲复合模

通过对面板零件的结构进行分析,研究了该零件冲压工艺方案,提出了采用剪切、弯曲复合模,并介绍了模具结构及工作过程,指出了模具主要工作部分零件的设计要求,从而保证了该零件的顺利成形。     

接线端子级进模具设计

通过对电器接线端子的结构进行分析,研究了该零件的冲压工艺方案,并介绍了接线端子零件多工位级进模的排样设计、工序设计、模具结构和动作过程,指出了模具主要工作部分零件的设计要求,从而保证了该零件的顺利成形。     

汽车前围板冲压数值模拟及工艺参数优化

针对汽车覆盖件冲压过程变形复杂的特点,对某型号汽车前围板零件拉深过程进行数值模拟,分析压边力及拉延筋的变化对该零件成形效果的影响.通过成形极限图优化压边力及拉延筋,最终获取该零件拉深工序合适的工艺参数,为汽车覆盖件冲压工艺提供快速、有效的设计方法.     

Touran轿车天窗框架冲压成形的数值模拟

应用LS-DYNA有限元软件,对Touran轿车天窗框架冲压成形过程进行了数值仿真,研究了框架易于失效沟槽处材料的变形行为,并预测了开裂产生的原因,同时对其成形后的厚度变化、变形安全裕度及天窗框架的材料选择进行了分析.仿真结果与实际冲压结果取得了较好的一致,证明了所建立的天窗框架仿真模型的合理性及计算结果的准确性,同时也进一步说明了材料性能对成形化具有显著的影响,为天窗框架冲压材料的选择提供了科学依据.     

基于结构-工艺协同优化的车门外板冲压成形

目的实现铝合金车门外板结构与冲压成形工艺参数的协同优化,解决零件冲压成形时破裂与过度减薄等问题。方法从材料流动与应力分布等角度入手,对车门的尺寸和形状参数进行优化,同时利用有限元分析软件AutoForm来获取一组最优的冲压工艺参数组合,最终通过产品的工厂试制进行验证。结果铝合金车门外板的冲压成形性大幅度提升,解决了车门外板冲压成形破裂等问题。结论研究结果对大型车身覆盖件的结构设计与冲压工艺有重要的指导意义。     

Feature-based metal stamping part and process design. Part II: stamping process planning

In metal stamping development, stamping process planning plays quite an important role for the related die design. As mentioned in Part-I [Feature-based metal stamping part and process design. Part 1: stampability evaluation, 2007, 45, 2673–2695], the feature can encapsulate comprehensive engineering information; this paper proposes to realize stamping process planning based on feature mapping. A feature mapping system, between a stamping design feature space and a stamping process feature space, has been presented. The inherent mechanism of such feature mapping has been investigated with formal representations. The substance of feature mapping is the processing of related knowledge and information. Mapping rules are established to generate the stamping operation and stamping direction. Four mapping manners (direct mapping, conjugate mapping, syncretic mapping, and sequential mapping) are presented for generating the form of process feature, through geometrical information transformation from design features. Meanwhile, considering a stamping process plan as an ordered tree, this paper has introduced how to build a stamping process plan through organizing the stamping operations mapped from design features, and an illustrative example is demonstrated.     

浅谈冲压工艺的精益管理

从冲压件设计及工艺、合理减少冲压工序、冲模的合理性、冲压设备的合理利用、劳动的有效性、零部件的通用性、合理工艺流程等七个方面详细分析了冲压工艺的精益管理，从而说明精益管理的重要意义，以便 于在产品设计、生产中降低产品成本，提高效益。     

高强度钢板U形件热冲压凹模结构拓扑优化

为降低热冲压凹模的生产成本和使用成本,基于板料热冲压数值模拟对凹模结构进行了拓扑优化设计.运用有限元软件ABAQUS建立热力耦合有限元模型,对高强钢板U形件的热冲压成形和淬火过程进行了数值仿真.提取凹模与板料间关键工况下接触应力作为凹模拓扑优化的外在载荷,建立约束凹模结构关键区域节点位移的体积最小化拓扑模型,对热冲压凹模结构进行拓扑优化设计,最终实现结构减重20%,且优化后凹模的变形和应力与优化前的结果相差甚微.研究内容对热冲压过程数值模拟和模具结构拓扑优化研究具有一定参考价值.     

超高强钢热冲压工艺信息化管理系统搭建研究

目的 解决超高强钢热冲压工艺参数多且参数调整范围大,造成热冲压工艺设计难度大的问题。方法 以微软SQL Server数据库和ASP.Net Core为平台,通过Visual Studio C#集成开发环境进行B/S（浏览器/服务器）架构程序开发。结果 实现了集成普通板、补丁板、拼焊板、软硬分区板、不等厚板、其他板共6类板材,15种零件类型,以及相关的零件信息、产品要求、制造工艺、材料属性、供应商、产线、设备等7类数据信息的超高强钢热冲压工艺信息化管理系统软件。结论 该系统实现了超高强钢热冲压工艺数据录入与存储,多种数据信息相互关联、按需检索与联合查询以及用户管理和维护功能,为国内超高强钢热冲压工艺技术研究与产品开发提供系统架构参考。     

缓冲器缸筒成形工艺

针对缓冲器缸筒产品结构特点及性能要求,结合热冲压(挤盂+热变薄拉深)及冷变薄拉深成形工艺的特点,对缓冲器缸筒成形工艺方案,热冲压(挤盂+热变薄拉深)毛坯的形状和尺寸,热冲压(挤盂+热变薄拉深)及冷变薄拉深成形工艺等关键技术问题进行了研究。试验结果表明采用热冲压(挤盂+热变薄拉深)和冷变薄拉深相结合的工艺方法对缓冲器缸筒进行成形加工高效而经济,比传统热冲压后机械加工的成形工艺原材料利用率提高25%左右,同时所生产的产品尺寸稳定,力学性能一致性好。     

A Comparative Study on the Production of a Hat Profile by Roll Forming and Stamping

Lightweight design using high-strength aluminum alloys has gained importance due to the continuing need for weight reduction and increasing crash safety requirements in the automotive industry. There are various manufacturing processes available for processing high-strength aluminum alloys. Herein, the production of high-strength aluminum parts by roll forming and stamping based on the example of an AA7075-T6 hat profile is compared. Roll forming represents a continuous manufacturing process, while stamping is a discontinuous process. Different process routes (T6, W-Temper and O) for roll forming as well as for stamping (T6, W-Temper, O and hot forming) are in focus of the investigation. Fundamental differences of the forming processes and the tempering condition are observed and criteria for the choice of the manufacturing process and process route are presented. The temperature-supported process routes improve the poor cold formability of AA7075 alloy and thus enhance the process window. Potential is offered for both manufacturing processes by applying tailored properties achieved through targeted quenching.     

Application of knowledge-based artificial immune system (KBAIS) for computer aided process planning in CIM context

In the present era, several manufacturing philosophies like lean manufacturing, total quality management (TQM), etc., have the goal of providing a quality product at reduced cost. In this research paper the process planning problem of a CIM system has been discussed where minimisation of cost of the finished product is considered as the main objective. For determining the cost of the finished product, scrap cost, forgotten by most of the previous researchers, has been considered along with other costs like raw material cost, processing cost, etc. In the present environment of concurrent engineering, optimisation of process planning is an NP-hard problem. To solve this complex problem a noble search algorithm, known as knowledge-based artificial immune system (KBAIS) has been proposed. The nobility of the proposed algorithm is that the inherent capability of AIS has been gleaned and incorporated with the property of the knowledge base. In this problem, the power of knowledge has been used for three stages in the algorithm: initialisation, selection and hyper-mutation. To demonstrate the efficacy of the proposed KBAIS, a bench mark problem has been considered. Intensive computational experiments have also been performed on randomly generated datasets to reveal the supremacy of the proposed algorithm over other existing heuristics.     

高强钢变厚板汽车B柱热成形数值模拟及主要参数分析

目的 研究热成形过程中冲压件温度场、应力场的变化规律,探究主要工艺参数对冲压件成形的影响规律。方法 利用Abaqus软件建立热力耦合模型,对汽车B柱的热冲压成形过程进行数值模拟,分析板料及模具的温度和应力变化,确定主要工艺参数对冲压件的影响规律,利用得到的规律指导B柱模具的设计与制造,最后对B柱进行冲压试验。结果 在热成形前的物料转移阶段,板材厚度差的存在使过渡区产生了温度梯度和内应力的变化;在热成形阶段,以减薄率为评判标准,确定了摩擦因数为0.35、冲压速度为100 mm/s时B柱的成形效果最好;对B柱的成形结果进行了分析,由局部减薄率的变化得到了模具缺陷的位置,由过渡区的偏移量得到了模具等厚区的长度,由板材温度变化确定了最佳保压时间为8 s。结论 基于Abaqus软件,构建了B柱的热冲压有限元模型,对板材出炉至成形结束阶段进行了数值模拟与分析,在此基础上对B柱制件进行了冲压试验,发现制件的质量缺陷明显减少,对制件的指定点进行了面检测,合格率达到了95.83%,表明了分析结果的可靠性,同时也验证了有限元分析的准确性。