Progressive Stamping Process Design And Optimization Of An Air-conditioning Value Bracket Based On Numerical Analysis

The stamping forming is a good forming quality, high efficiency and low costmethod which widely used in machinery, vehicles, light industry, household appliances,electrical instrumentations and other modern manufacturing industries that can’t bereplaced by other processing methods. And the multi-step progressive die is highproduction efficiency and the most suitable for mass production applications which hasbecome increasingly widespread used as a practical stamping die of efficient,high-speed, high-quality and longevity. Because of the progressive die always has morestations, the mold structure is complexity, needs high technology and experience, thedesign and development is difficult. So it makes the application of progressive die isdifficult. In this paper, an air-condition value bracket is researched as an object. And itsprogressive forming process is analyzed and optimized through numerical analysis andresponse surface optimization method which shortening the progressive diedevelopment cycle and improving efficiency.First, the forming process of the part is analyzed and different progressive formingprocess is proposed. Combined with the numerical analysis software DYNAFORM, anew finite element modeling method that multi-position single process combined withmulti-process multi-station for progressive forming is proposed, which is closer to theactual level of progressive forming in the simulation, but different from the traditionalprogressive die modeling method. The whole process of progressive forming issimulated through the finite element mode established for the part. The program isoptimized according to the simulation results, and the reasonable progressive stampingprogram is determined through the analysis of the optimized solution.Then, the response surface method is used to optimize the forming parameters. Themovement of the pilot hole is regard as the evaluation index for the forming precision,the maximum thinning is regard as the evaluation index for cracking and the maximumthickening is regard as the evaluation index for wrinkling. The maximum thinning andmaximum thickening are counted as constraint functions, the movement of the pilothole is counted as objective function, the forming parameters: blank holder force,friction coefficient, the clearance between punch and die are counted as design variables.The mathematical model of constrain functions and objective function are obtainedthrough experiment and simulation results. The objective function is optimized based on constraints, and the optimal combination parameters: the blank holder force is29KN,the friction coefficient is0.13, the clearance between punch and die is1.11t areobtained.Finally, according to the determined progressive stamping process, the optimalforming parameters are used in the actual production, and the qualified part is obtainedthrough the die trial. Which verified the finite element simulation and parameteroptimization on progressive die design and forming process is feasible, and it alsosignificantly reduces the mold design and development cycle and greatly improvesproduction efficiency.