Study On The Rolling Hemming Process Of Thermal Insulation Board

With the development of society,people are demanding higher and higher levels of car comfort,prompting the automotive industry to make greater improvements in automobile insulation and noise reduction.Thermal insulation board can not only reduce the temperature conduction to the cab,but also can play a certain role in noise isolation.In this paper,the research on the forming process of the insulation of the 1050 aluminum alloy is established.In this paper,the three-dimensional finite element model of 1050aluminum alloy rolling hemming and embossing process was established.Based on the above model,the effects of flanging height,TCP-RTP distance,roller radius,fillet size and rolling speed on the forming of the edge were studied through a series of orthogonal simulation experiments of L₁₆?4⁵?.The results show that the influence degree of the 5factors on the corrugation wave amount is:the height of the flanging>the radius of the roller>the TCP-RTP value>the radius of the round angle>the rolling pressure.The influence degree of the 5 factors on the expansion amount is the radius of the circle>the rolling speed>the height of the flanging>the radius of the roller>the TCP-RTP value.Then,each level of each factor is selected by the control variable method,and a set of optimal parameters is finally selected.Then,the curvilinear curling and edging models with different curvatures were established,and the models with different curvatures were analyzed by using the optimal parameters.The results show that the curvatures of 1050aluminum alloy curved curling which is suitable for the rolling hemming process should not exceed 0.011,and the curvature of the smaller the better forming roller hemming.Then,the forming experiment of the rolling process of 1050 aluminum alloy roll forming process was set up.The influence of TCP-RTP value in the rolling process was studied by the control variable method.When the TCP-RTP value is between 0.8mm-1.0mm,the corrugation wave amount increases with the increase of TCP-RTP value.At1.0mm-1.5mm,the amount of corrugation decreases with the increase of TCP-RTP value.When the TCP-When the RTP value is 1.5mm,the corrugation wave amount reaches the minimum.When the TCP-RTP value is in the range of 0.8mm-1.5mm,the expansion amount decreases with the increase of TCP-RTP value.The experimental results show that the optimal parameters of the corrugation wave amount are 5.56%different from the simulation value,and the difference between the experimental value and the simulation value is of the expansion amount 5.62%.Finally,the three-dimensional finite element model of 1050 aluminum alloy double-roller rolling hemming and embossing process was established.Based on the above model,the effects of flanging height,TCP-RTP distance,roller radius,fillet size and rolling speed on the forming of the edge were studied through a series of orthogonal simulation experiments of L₁₆?4⁵?.The results show that the significant ranking of the influence of the process parameters on the corrugation wave amount and the expansion amount of the wave are respectively as follows:flanging height>roller radius>TCP-RTP distance>fillet size>rolling speed;fillet size>rolling speed>flanging height>roller radius>TCP-RTP distance.The influences of various factors on the corrugation wave amount and the expansion amount were also studied.The mechanical causes of the defects were analyzed.The critical values of the corrugation wave amount and expansion amount of the 1050 aluminum alloy sheet in the rolling hemming were 30 MPa and 20 MPa.According to the results of orthogonal experiment,the optimal parameters were selected to simulate and experiment.The results show that the corrugation wave amount and the expansion amount are 0.042mm and 0.498mm respectively,the forming quality is pretty high.The feasibility of the double-roller rolling hemming is proved.