Research On Stamping Process Of Automobile Right Door

With the development of the economy,the increasing people's demands for the quality and the appearance of automobiles have accelerated the research and development of new type of automobile.The stamping forming technology of automobile body panels has become an important factor in the research and development process.With the development of computers,finite element numerical simulation can shorten the research and development cycle,improve the reliability of mold design,and significantly reduce the production cost of products.In this paper,the auto right door part is taken as the research object.The numerical simulation analysis of the forming process has been carried out by using the finite element software Autoform.The defects like insufficient stretch,wrinkling and failure during the sheet forming process have been predicted by the simulation analysis.The simulation results have been optimized by adjusting the blank holder force,drawbead parameters,convex and concave mold clearance and friction coefficient.Meanwhile,the effects of various influencing factors on the springback of the auto right door have been studied.The orthogonal experiment has been used to optimize and obtain a set of proper process parameters.Based on the simulation results,the forming molds have been designed,forming experiments have been performed to obtain the qualified parts.The main conclusions of this paper are as following:(1)The spatial structure of the auto right door part of the automobile is relatively complicated.The preliminary forming simulation shows that the defect of the insufficient stretch is more likely to occur during the stamping process of the auto right door part.This defect will seriously affect the rigidity and accuracy as well as the use of of the product.According to the structural characteristics of the auto right door,the double drawbeads with variable strength are set.It can effectively control the insufficient stretch of the auto right door.(2)The influence rules of blank holder force,mold clearance and friction coefficient on the deep drawing formability of the auto right door have been studied by numerical simulation.By properly increasing the blank holder force and frictioncoefficient,the flow resistance of the sheet metal can be increased.The blank holder force,the friction coefficient and mold clearance are temporarily set to be 650 kN,0.15 and 0.80 mm,respectively.The maximum failure value of the auto right door reaches the smallest.(3)The effects of blank holder force,mold clearance and friction coefficient on the springback of the auto right door have been studied by orthogonal experiment.The friction coefficient has the greatest impact on the sprinback of the auto right door part,followed by the mold clearance.The blank-holder force has the least impact on the springback.Combined with the forming simulation results of the auto right door,the proper combination of forming process parameters for the auto right door has been finally optimized: the blank-holder force 650 kN,the mold clearance 0.80 mm,and the friction coefficient 0.15.The maximum springback value of the final part is 1.327 mm,which meets the actual production requirements.(4)Based on the relevant data of numerical simulation,the mold design of each stamping forming for the auto right door part and the forming experiment have been carried out,respectively.The forming experiment results of deep drawing,trimmingpunching and flanging of the part are consistent with those of numerical simulation,meeting the requirements of the product.The accuracy of the results of numerical simulation research is verified.