Research On The Stamping Forming Of The Three-in-One Overall Structure Of The Cab Floor Longitudinal Beam Of A Light Truck

As the main force of logistics transportation,China's commercial vehicles have encountered unprecedented opportunities for development under the background of rapid economic development,the production technology level of independent brands of commercial vehicles has been greatly improved,but there is still a considerable gap relative to the advanced level in foreign countries.Compared with other commercial vehicles,China's light trucks have earlier development time and more mature technologies,and the flat-headed cab is the mainstream of the design.Since China's economic growth has slowed down in 2012 and the national automotive product emission standards and related policies have tightened,the domestic light truck market is facing huge challenges,whether it is possible to shorten the development cycle of light trucks,reduce the production cost of light trucks,and improve the quality of light trucks have become an important factor for whether light truck manufacturers can survive in the light truck market,therefore the design and manufacture of the cover mold has become an important part of the light truck development process.The cab floor longitudinal beam is a very important structural part in the development of the light truck cab,it's structure is complex,and it's main function is to support the entire cab,as a benchmark in the cab assembly process,the forming quality is related to the strength and stiffness of the cab floor and the assembly quality of the entire cab,the assembly quality of the entire cab has always been the focus of developers' research.This article takes the floor longitudinal beam of the "Light Truck 2250" cab development project of Shandong Xiaoya Precision Machinery Co.,Ltd.as the research object,firstly creatively proposes to develop the split-structures of the longitudinal beams of the front,middle,and back sections to form a three-in-one overall drawing structure under conditions that satisfy various performance requirements of the floor stringers without changing the general structure,and according to the characteristics of the overall structure of the longitudinal beam,complementary design of the squeezing ribs and process holes.Although the difficulty in forming the floor longitudinal beam has been improved,the three-in-one design can significantly shorten the mold design and manufacturing cycle,significantly reducing costs.Then DC01 cold-rolled steel was selected as stamping material for the structural characteristics and forming requirements of the three-in-one overall structure of the floor stringer,and the forming process plan was determined.Based on the product number model,using Autoform software to determine the stamping direction,the design of the binder surface and the supplementary surface,the design of the drawing ribs,and the design of the blank shape and size.Then use Autoform software to simulate the forming of the floor longitudinal beam,optimize the forming parameters according to the forming simulation results and determine the optimal forming parameter scheme.Finally,using the UG software to draw three-dimensional die layout diagram based on the optimized process parameters,and complete the design of the three-dimensional structure diagram of the whole-sequence mold for floor longitudinal beam,and proofread the three-dimensional structure of the mold.Track the whole process of mold production,assembly,manufacture and debugging,and propose corresponding solutions according to problems such as cracking and wrinkling in the stamping parts during mold debugging.Test the stampings with a customized inspection tool,and rectify the molds based on the inspection results,finally the molds have been accepted and delivered to the customer for production.