Simulation Research On The Forming Of Longitudinal Extended Plate And Its Engineering Application

The longitudinal extension plate is one of automotive panel, it is difficult to form high-precision automotive covering parts because the covering parts mostly has complex curved surface and it is always produced with some defects such as crack, winkle and springback in the actual production. The traditional method of die testing and seeking the optimal process scheme by experience cannot guarantee the product quality and prolong the product development period. In addition, with the development of CAE technology, it becomes feasible to determine whether the process scheme and die structure is reasonable in advance by modern numerical simulation technology, which greatly reduce the workload of die testing and has an important practical significance on determining forming process, improving product benefit and reducing production costs.This paper takes the car extension girder plate of CS10 project in Shandong xiaoya precise machinery company as the research object and studies how to design forming process and die structure and to determine the optimal process scheme.First of all, the material parameters measured by the tensile test are used to establish material model in the Material Generator module of Autoform software, which ensures the accuracy of the simulation results in the process of numerical simulation. Meanwhile, product process analysis was carried out and then initial process scheme was determined according to the analysis results.Secondly, model surface including profile, addendum and blinder surface were designed and many parameters were set such as drawing direction, trimming direction, blank holder force by the means of the Autoform software. Then analyze the initial process scheme by numerical simulation and improved the initial scheme according to simulation results.Then, orthogonal experiment was arranged by considering four significant forming parameter, which include bland holder force, friction coefficient, Drawbead resistance factor and die rounded corner. The optimal parameter combination was determined using the intuitive analysis that is used to analyze experience results and the variance analysis that is applied to verify analysis results.Finally, DL diagram were designed according to the optimal process scheme and the mold three-dimensional structure was designed using UG software and tracking the whole process of mold manufacturing. Then, grid strain measurement test was carried out to analyze die testing sample, which instructs to debug mold.