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基于有限元分析软件eta/DYNAFORM,对汽车前指梁的弯曲成形、预成形及内高压成形工艺过程进行了数值模拟。在弯曲成形工步中,研究了管坯各个弯曲位置在相同弯曲半径、不同弯曲角度下的壁厚分布;在预成形工步中主要分析了预制坯形状对前指梁内高压成形的影响;在内高压成形工步中,研究了优化后的预制坯形状对最终成形零件成形缺陷的影响。基于有限元模拟结果,分别进行了弯曲成形、预成形和内高压成形试验。研究结果表明:预制坯形状是决定前指梁内高压能否顺利成形的重要因素;通过改变预成形模具的结构形式,可以得到合理的预制坯形状,避免内高压成形过程中缺陷的产生。实际成形试验结果与数值模拟结果基本一致。
Based on the finite element analysis software eta / DYNAFORM, the bending, pre-forming and inner-high-pressure forming process of the automobile front finger beam are numerically simulated. In the bending step, the wall thickness distribution of the tube bending at the same bending radius and bending angle was studied. The influence of the preform shape on the high pressure forming in the front finger beam was mainly analyzed in the preforming step. In the high-pressure forming step, the influence of the optimized preform shape on the forming defects of the final formed part was investigated. Based on the finite element simulation results, the bending forming, preforming and internal high pressure forming tests were carried out respectively. The results show that the shape of the preform is an important factor that determines whether the high pressure in the front finger beam can be smoothly formed. By changing the structure of the preform, a reasonable preform shape can be obtained and the defects in the forming process can be avoided. The actual forming test results and numerical simulation results are basically the same.