Process Optimization And Springback Control Of Aluminum Alloy Side Wall Outer Plate Based On Stamping Synchronous Engineering

Synchronous engineering is a systematic method to advance the part process design process to the product design stage,and systematically consider all factors in the stamping process from structure establishment to finished product manufacturing.Starting from the development project of a large segmented SUV side panel die,based on the stamping Synchronous Engineering,this paper studies its application in each stage of the development of aluminum alloy side panel outer plate.Firstly,this paper introduces the research status of stamping Synchronous Engineering,combined with the experience support of enterprise PDM system,reviews the block process of an aluminum alloy side wall outer plate,puts forward the preliminary structural optimization scheme conducive to stamping manufacturing,and formulates the whole process stamping process schedule.Then the full sequence analysis is carried out by using the finite element analysis software Auto Form,and the second structural optimization of the parts is carried out according to the analysis results.The simulation results show that optimizing the original part modeling in the synchronous engineering stage can avoid stamping defects in the design: expanding the fillet of the cracked area and creating steps can alleviate the risk of cracking;Setting reasonable transition shape in continuous step wrinkle area can alleviate wrinkle;Designing stiffeners and adding structural constraints can improve the problem of insufficient deformation in the forming process.Aiming at the wrinkling defect of the pressing surface found in the trial production of the sample,based on the CAE analysis results,this paper puts forward the punch structure optimization to improve the gravity state of the sheet metal and the blank holder structure optimization scheme to facilitate the material flow.Considering that it may be difficult to reconcile cracking and wrinkling in the optimization area,a double-objective drawing process parameter optimization based on BBD test response surface and NSGA-II genetic algorithm is proposed through comprehensive analysis.The specific process optimization parameters are blank holder force,friction coefficient,drawbead resistance coefficient and die fillet.Then the non inferior optimal solution of the calculated process parameters is scored by entropy method,The process parameter scheme with the highest score is the best process parameter.The optimized combination of process parameters finally determined in this paper is blank holder force 1900 kn,friction coefficient0.1,drawbead resistance coefficient 0.1 and die fillet 25 mm.Finally,during the springback treatment,it is found that the springback defect in the rear insurance area of an aluminum alloy side wall outer plate is not sensitive to the change of drawing process,so it needs springback compensation.Through the comparative study,it is found that the springback compensation efficiency of the whole process replacement compensation of parts is significantly higher than that of only drawing compensation.The overall rebound efficiency can be compensated initially,and then the local rebound efficiency can be optimized.This paper also compares the influence of the difference of different compensation coefficient K on the springback compensation efficiency,and finds that the best springback compensation coefficient K for the local compensation of the rear bumper is 0.75.The "2mm" project is used to evaluate the springback quality of the post insurance area of the qualified parts manufactured by this scheme after blue light scanning.The results show that the qualified rate is 98.3%,which is not much different from 100% of the qualified rate of the simulation results.It is proved that this method can effectively reduce the time and cost of later stamping die development,and provide a good design reference for similar parts.