Numeircal Simulation For Blanking Of U-shaped Adjusting Shim

In recent years，with the rapid development of domestic and foreign rail vehiclemanufacturing industry，body manufacturing technology and product quality rail vehiclemanufacturing industry has attract more and more attention to home and abroad.Considering the problem such as vehicle body mass and manufacturing precision，thebody rail cars in our country are mostly aluminum body and stainless steel body.Car bodyadjustment shim which is an important component of the vehicle body is used to adjustthe height of the mechanical device in the body， the gap between the parts andcomponents of connection，whose quality directly affects the subsequent rail vehicleassembly work. Car body adjustment shim processing belongs to the punching blankingprocess.Thus the study of the punching technology is essential.At present，the blanking pieces finished by punching blanking process still existmany defects，such as uneven surfaces，poor quality of cross section and larger burr，which not only reduce the efficiency of the actual production，but also increase thefollow-up process. In addition to addressing these problems，we still need to have adevelopment and research to adjust gasket blanking die. Excessive mold replacement is auseless consumption.The development of adjustment shim mold reduces cost andimproves production efficiency.In this paper， there is a simulation research for theabove two major problems existing the reality in application of DEFORM-3D software.The specific contents are as follows:（1）There is simulation analysis on adjustment of gasket cracks in the processof blanking，extension，and the fracture process. Secondly，there is numerical simulation study the adjusting gasket blanking process made by plate thickness is2mm aluminum alloy5083-O and stainless steel301L-ST，which analyzes of the impac t of convex and concave die clearance blanking section quality and determines the reasonable range of die clearance and optimal blanking clearance value.Reasonable die clearance of2mm aluminum alloy5083-O (bilateral gap) is in the range of3%t~5%t(0.06mm~0.1mm).The optimal value of blanking clearance is3%t (0.06mm).Reasonable die clearance of2mm stainless steel301L-ST is in the range of5%t~7%t (0.1mm~0.14mm).The optimal value of blanking clearance is5%t.Doing comparison the simulation results of these two kinds of materials，we study on materials properties hedge cutting surface of the influence of the proportion of each part.（2）Studying on the effects of clearance between convex die and pressure plate forblanking section quality，we determine the optimal value convex die and pressure plate tomake the best quality punching section. When convex，concave clearance is0.06mm (3%t)，and the gap between convex die and pressure plate is0.05mm，2mm aluminum5083-Oadjustment shim is the best one to get the best cross section quality of blanking pieces.（3）Combining with numerical simulation technology，we study on the feasibilityof U shape adjusting gasket general die development. We research a kind of generalblanking mold for different thickness of the adjusting gasket cutting processing under thesame process parameters. The results indicate that0.5mm and1mm aluminum alloy5083-O sheet can be punched on the same set of0.02mm punching mold gap.1.5mm，2mm，2.5mm and3mm aluminum alloy5083-O sheet can be punched on the same set of0.075mm punching mold gap.4mm and5mm aluminum alloy5083-O sheet can bepunched on the same set of0.36mm punching mold gap. In addition，thickness of0.5mmand1mm stainless steel301L-ST sheet can be punched clearance on the same set of0.02mm punching mold gap. Thickness of1.5mm2mm2.5mm and3mm stainless steel301L-ST sheet can be punched clearance on the same set of0.105mm punching mold gap.Thickness of4mm and5mm stainless steel301L-ST sheet can be punched clearance onthe same set of0.36mm punching mold gap.Based on the above numerical simulation research，this paper carried out car body Uadjust gasket blanking experimental study， which verify of the accuracy of optimalclearance values and the feasibility general mold development. The optimal die gap value and gasket general mold development technology in thisPaper have been applied in Changchun railway vehicles U shape adjustment shimproduction. Then，the feedback effect is good.