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针对摩托车油箱外壳成形缺陷,采用Dynaform软件对油箱外壳双片组合成形(Double-Cover Forming,DCF)过程进行了数值仿真分析,仿真结果表明侧壁起皱和局部破裂是主要缺陷。利用数值模拟与正交试验设计(Orthogonal Experimental Design,OED)相结合的方法分析和优化了拉延筋高度和压边力参数,分析表明适当增大拉延筋高度和压边力可有效抑制起皱缺陷。采用优化后的参数进行制件压延成形试验,结果表明制件成形均匀性有了较大改善,成形质量得到提高。
In order to deal with the forming defects of the motorcycle fuel tank shell, the numerical simulation analysis of the Double-Cover Forming (DCF) process was carried out by Dynaform software. The simulation results show that the wrinkling and the partial rupture of the sidewall are the main defects. The combination of numerical simulation and Orthogonal Experimental Design (OED) was used to analyze and optimize the parameters of drawbead height and blank holder force. The analysis shows that proper increase of drawbead height and blank holder force can effectively suppress Wrinkle defects. The optimized parameters were used to test the calendering of the parts. The results showed that the forming uniformity of the parts has been greatly improved and the forming quality has been improved.