Research On Stamping Simulation And Process Optimization For Spring Seat

During the development of stamping die design process,it is often encountered that the process parameters are unreliable according to the experience formula design,due to the change of material properties and stamping process.The numerical simulation technology of sheet metal stamping provides an efficient technical approach for stamping die design.Spring seat is atypical stamping part.The research on its stamping performance and regularity by adopting numerical simulation technology,can not only improve the product quality,but also enrich the research content of multi-step stamping.The main work of this paper is as follows:(1)The stamping manufacturability of the spring seat was analyzed from the aspects of shape size,material property and precision requirements.It is estimated that the blank size was 140mm×140mm and the material utilization rate was 72.65%.(2)Multi-step stamping process of spring seat,including drawing,sizing,trimming,forming,piercing and hole flanging were designed to meet the requirements of structure and stamping quality,by the means of numerical simulation technology and inverse unfolding approach.And a numerical model was established to simulate the whole 6 steps stamping process.(3)The stamping results of each process were analyzed.In order to avoid the excessive thinning and rupture defects in the flanging process,a chamfering process was add before the flanging process.For the wrinkling defects of the helical surface in the forming process,the die clearance,the edge-pressing force and the friction coefficient were selected as the variables,the wrinkling and thickness uniformity were taken as the stamping quality evaluation indexes,the function relation between the stamping quality evaluation indexes and the variables was obtained by using the response surface method.And the optimal stamping parameters were obtained: The mould clearance c=2.42 mm,the blank hold forces F=10.18 kN and the friction coefficient ?=0.13.Compared with the data before optimization,wrinkle index decreased by 31.72% and the thickness uniformity index decreased by 2.85%.(4)By using the optimized stamping process and stamping parameters,the stamping test was carried out.The stamping die structure of each process was also introduced.And the 72 stamping indexes of prototypes were detected through visual inspection,checking fixtures and measuring instruments.The test results show that the prototypes have reached the quality requirement of the parts,besides,the reliability of the numerical simulation results and the effectiveness of the process optimization scheme were also validated.