Simulation And Process Optimization Of Stamping And Forming Of Automotive Seat Sheet Metal Parts

Automotive light weighting refers to reducing the overall vehicle mass and reducing fuel consumption while ensuring the safety of the vehicle.The use of high-strength steel to make sheet metal parts is the main way of automotive light weighting.However,highstrength steel has the disadvantages of high forming difficulty,low forming accuracy and easy to break,so it is important to design and optimize the stamping process of highstrength steel sheet material by using stamping and forming simulation method.An automatic seat sheet metal part is taken as the research object in this thesis,the simulation of stamping and forming is carried out first,and then the process optimization is carried out according to the simulation results.Subsequently,the simulation results are verified through actual tests to prove the effectiveness of the simulation and process optimization methods of stamping and forming.The main research contents of this thesis are as follows.(1)Stamping and forming process design and numerical simulation of sheet metal parts.After understanding the characteristics of the stamping process,the sheet metal parts are subjected to process analysis,and the sheet metal stamping process is designed.Then on this basis,detailed design of each process is carried out,including stamping direction,process supplement and relevant parameter setting,etc.Finally,based on the study of sheet metal forming theory and processing of geometric models,sheet metal parts are subjected to numerical simulation of stamping and forming,and the quality of stamping and forming of sheet metal parts is analyzed to determine whether the sheet metal parts meet the production requirements.(2)Analysis and optimization of stamping and forming quality of sheet metal parts.The forming defects of the sheet metal parts are analyzed according to their forming quality,and two kinds of forming defects,namely,cracking and wrinkling are optimized.Optimization of cracking defects is carried out by optimizing the shape of sheet metal,adding process notches and optimizing stamping dies,and optimization of wrinkling defects is carried out by adding deep drawing rib structure.The overall forming quality is improved while eliminating cracking and reducing wrinkling.In addition,the relationship between the relevant important process parameters and the forming quality are studied and analyzed,and the maximum range of the process parameters is given.(3)Research and control of rebound characteristics of sheet metal parts stamping.The rebound of sheet metal parts is analyzed and the important factors affecting the rebound are studied,including material properties,sheet metal part structure,material thickness and process parameters.Then,according to the relationship between the process parameters and the maximum rebound of the sheet metal parts,the better process parameters are selected for the orthogonal test,and the optimal combination of process parameters is obtained with the maximum rebound as the index.Finally,sample trial production is carried out,and the sheet metal part samples are tested by special gauges,related stiffness and strength tests,which proved the effectiveness of the stamping and forming simulation and process optimization methods.