Research On Key Technologies Of Multi-position Progressive Stamping For Heat Exchanger Fin

With the increase of technology development and level of people’s living standard, air-conditioner has been replacing electric fan gradually to become the main refrigerant facility. Generally, every air-conditioner consists of hundreds of fins, therefore the demand of fins is very huge. In order to satisfy the large demand of air-conditioner fins, technologies of progressive stamping are adapted. Therefore, it’s very important to explore the multi-position progressive die for manufacturing of heat exchanger fin; forming quality of fins, especially for drawing and and flanging process, can be analyzed by using the numerical simulation technology, which can reduce the die trial and cost. Additionally, the stamping force can also be obtained to research the vibration of high-speed punching machine, which has the vital practical significance.The air-conditioner fin was taken as researched object in this paper, the separation process(punching, cutting blind window, trimming and splitting)and forming process(drawing, flanging and second flanging) of which are simulated by the commercial finite element analysis software Deform-3D and Dynaform; forming defects were solved and the stamping force curve of each position were obtained; in order to acquire the force curve, one set of multi-position progressive die was designed; the test results and the simulated results have been compared to verify the reliability and rationality of the simulation. The main research contents and conclusions of this paper are summarized as follows:(1) The whole progressive stamping for air-conditioner fin by the method of multi-position and multi-process was simulated; finite element modeling and numerical simulation of the process of multi-drawing, flanging and second-flanging were carried out with the software Solidworks and Dynaform; the forming quality(cracking and the nonuniformity of flanging height) and force of each process based on the result of numerical simulation were analyzed.(2) Taking the air-conditioner fin’s separation process as the studied object, finite element models of the processes of punching, cutting blind window, trimming and splitting were established by using the software Solidworks and Deform-3D; through the numerical simulation of these processes mentioned above, the curves of cutting force were obtained; and the effect of blanking clearance on the force of punching, trimming and splitting was analyzed.(3) One set of multi-position progressive die for stamping test was designed, which including the drawing sub-module, the punching sub-module and the flanging sub-module. Feeding of the multi-position progressive die can be realized by the method of one-step; and the progressive die consists the positions of five-steps drawing, punching, flanging, which can be used to prove the simulation of forming and separation process through stamping test.(4) The calibration test for PVDF sensor was implemented. Firstly, the PVDF sensor was packaged to prepare for the stamping force test; secondly, the quantity of electricity from the PVDF sensor was compared with the normalized force from the shock testing machine; finally, the dynamic piezoelectric coefficient of PVDF sensor was obtained.(5) Research of stamping test was completed. The progressive stamping test of air-conditioner fin based on the GPS-110 servo press machine was carried out. Using the PVDF sensor, the force of each process and the curve of stamping force were collected; the test results and the simulated results were compared to verify the precision of simulated model made in Dynaform and Deform. The research on key technologies of multi-position progressive stamping for heat exchanger fin in this paper can make outstanding contributions in providing guidance for the stamping forming and the dynamic measurement of stamping force.