Experiment Design And Numerical Simulation Of Crimping Process For Turbo Actuator

With the continuous development of science and technology, the processing technic for metal forming is constantly improving, and people's requirements for the accuracy of metal forming are getting higher and higher. Hemming, also called crimping, is a relatively common processing method to connect an outer plate with an inner plate. Crimping is usually the final process of metal forming, so the quality of crimping has a particularly influence on the forming process of sheet metal especially on the outer covering part.This paper mainly studies the crimping process of turbo actuator at passenger vehicle. Firstly design a series experiments with a method of orthogonal test, then study and analysis the crimping results both by single factor visual analysis and multi-factor orthogonal matrix analysis, finally it concludes the influence tend of the main three process parameters at crimping including surface bevel ? and contour radius R of upper die and stamping pressure P on the main three forming quality indicators including E, F and thickness T of actuator's cross section dimension. Moreover it puts forward an optimal process parameters combination of one actuator's crimping process and verifies the conclusion by sample statistical analysis in continuous trail run production.With the analysis of crimping process for Turbo Actuator based on multi-target orthogonal test and the conclusions obtained, this paper also studies the crimping process of Turbo Actuator by using the finite element method. Firstly establish the 3D model of actuator and the 3D model of both up die and down die; then using Hypermesh to mesh the models, define the material parameters, set constraints and contact type etc., also set the simulation time and output control in Hypermesh to complete the pre-processing; what follows is to operation the simulation process in LS-DYNA solver; finally, extraction the related simulation results in the post processing software LS-PrePost. Next, do a further research and analysis on the simulation results by compared it with the results get from both orthogonal test and actual production, after confirm the feasibility of the simulation method can further adjustment the parameters of crimping process, and finally concluded the optimal combination forming parameters of crimping process for Turbo Actuator.Therefore, this paper hope that by design an experiment use the method of orthogonal test and numerical simulation analysis, then select some important process parameters which mainly effect the quality of turbo actuator after crimping, then analyzes its impact on a single forming dimension result and its cross influence on each dimension result, finally select an optimal combination of process parameters for crimping process of actuator, so as to improve the design quality of mold and reduce mold production cycle time in practical production, also to reduce scrap rate and the production cost.