Research On Numerical Simulation Of Aluminum Profile Stretch Bending And Compensation Method For Springback

The stretch-bending process of aluminum profiles iswidely used in the engineering field,and is a key forming technology for the manufacture parts such as automobiles and rail vehicles.The stretch-bending is complicated,and there are problems such as cross-sectional deformation and springback of the parts after forming,which seriously affects the forming accuracy and surface quality of the parts..Therefore,it is of great significance to improve the quality of stretch-bend forming parts and reduce production costs.This paper mainly studies the stretch-bending forming process of the A6043 aluminum profile of the vehicle luggage rack.The finite element simulation technology is used to systematically study the stretch-bending forming process and the forming law of the profile,and the influence law of the process parameters on the springback is obtained.With the best process parameters,qualified parts are obtained by optimizing the mold surface,and the corresponding secondary development is carried out to improve work efficiency.The main work completed in this paper include:(1)The finite element model of stretch-bending forming is established.Simulation experiment is conducted using response surface methodology to analyze the effects of major process parameters,namely pre-stretching,coating stretch,supplementary stretch,and friction coefficient on the springback of the profile after stretch-bending forming.(2)Optimization of stretch-bending forming process has been completed.Through the simulation test,the relationship between the springback and process parameters,pre-stretching,coating stretch,supplementary stretch and friction coefficient are obtained.The best process parameters are: 0.8% of pre-stretching amount,4% of coating stretch amount,0.8% of supplementary stretch amount,and 0.1 of friction coefficient.(3)The compensation algorithm of the mold surface is researched.On the basis of the best process parameters,a finite element model and process parameters are established for stretch bending numerical simulation with different curvature molds.The difference method and the chord method are respectively applied to iteratively modify the bending mold of single and double curvatures for mitigating the springback of aluminum profile,within acceptable errors.(4)Finally,a functional plug-in for stretch-bending forming is developed.In order to improve work efficiency,the two simulations of bending and springback are combined to form a modeling platform developed by GUI,which is verified by testing and compared with the calculation results of manual modeling.The results show that the platform can efficiently and effectively fulfill the preset requirements.