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分析了汽车冷却器缓冲罩的结构特点和冲压工艺特性,制定了该零件成形工艺方案。运用Dynaform软件对其多工位级进冲压过程中主要涉及的拉深、整形、冲孔、翻边等工序进行数值模拟。分析了每个成形工序的板料成形极限图(FLD)和零件壁厚分布图,模拟结果符合零件成形要求。据此设计出该零件12工位的级进冲压模具,试模生产出了合格的产品。通过对模拟和试冲结果相比较,其零件厚度的最大相对误差为2.87%,获得了较好的一致性。目前该汽车冷却器缓冲罩级进模已投入大批量生产。
The structural characteristics and stamping process characteristics of the automobile cooler cushion cover are analyzed, and the forming process scheme of the part is established. Dynaform software is used to simulate the processes of deep drawing, shaping, punching and burring which are mainly involved in the multi-station progressive stamping process. The sheet forming limit (FLD) and part wall thickness distribution of each forming process are analyzed. The simulation results are in accordance with the requirements of part forming. Accordingly, the design of the parts of the 12-stage progressive stamping die, test-mold production of qualified products. The maximum relative error of the thickness of the part is 2.87% by comparison with the simulation and test results, and better consistency is obtained. The car cooler cushion cover progressive die has been put into mass production.