Stamping Simulation And Process Optimization For Spring Seat

Because of its spiral surface which causes asymmetry, the deformation state of spring seat in the stamping process is much more complicated than that of general symmetry part. Accordance with the original production process,as the thickness distribution of drawing workpiece is extremely uneven in key positions, boss,thickening and thinning are too serious to meet the quality requirements of product;workpiece of flanging has risk of crack;in the hole flanging operation,cracks extremely easily occur on the edge of U-notch,which make the quality of product too difficult to control.In order to overcome the defects and ascertain the forming characteristics of the spring seat, using numerical simulation technology, this paper establishes all of the numerical simulation models of the forming process which include drawing,flanging, and hole flanging.The deformation characteristics of drawing workpiece in the key positions are presented by several feature points.Through the multi-step simulation in this paper, the transfer about thickness, strain and other information are well reflected.The information of thickness and strain in diferent operations show that the forming quality which evaluationed by the previous operation does not suffer the influence of the next one. Therefore, the overall quality of spring seat can be improved in the manner of improving the quality of defective position step by step,by carrying out single operation.In view of the drawinig workpiece's forming quality problem, two regression models between the process parameters and the rates of maximum thinning and thickening are established by regression analysis using punch profile radius and die clearance in the part of the boss, based on simulation test. According to the regression models mentioned just now,multi-objective optimization is achieved and an model of overall quality is educed. Optimum parameters that can produce qualified workpiece are figured out.Aimed at the quality status of flanging workpiece, feasibility of process parameters are tested,and its available values are displayed which make quality improvement can be achieved just by adjusting die clearance, die profile radius or punch profile radius.In order to prevent cracking phenomena from occurring on the edge of U-notch in hole flanging process, orthogonal test is taken to find reasonable process parameters.The test result showing that it is difficult to overcome the defects of product completely by adjusting process parameters, which indicates that operations need to be ameliorated.By rectifying punching and hole flanging,the quality of the spring seat is ensured.