Optimization Of The Composite Forming Process Of The Front Girder Of Automobile

In order to meet the need of energy conservation and emission reduction,the application of automobile lightweight technology has become an important development direction of automobile manufacturing industry.Automobile lightweight requirements to reduce body weight at the same time to ensure its safety,so all kinds of high strength lightweight high strength steel plate was developed,more and more enterprises use high strength steel plate manufacturing automobile body covering parts,and key components.The front girder connecting plate of a car’s front longitudinal beam is a part of its side girder frame,which needs to bear the load requirements of the car frame,and requires certain rigidity.The part which the thickness of 2.0 mm cold rolled steel(SPCC)as material,in order to reach the goal of reducing weight,use of high strength steel plate SPFC440,its thickness is 1.2 mm,but in the process of stamping process prone to dark crack and even broken.In this paper,previous girder beam connection plate as the research target,using the method of finite element simulation of sheet metal stamping,longitudinal beam before the beam connection plate 3 d model,the simulation of the stamping deformation process,cloud,forming limit diagram analysis sheet thickness change;The optimum process parameters were obtained by orthogonal test analysis to eliminate the dark crack and improve the qualified rate.Based on the illustration of the identity of body parts used in manufacturing the status quo,the defect of stamping and finite element simulation theory,on the basis of longitudinal beam before the beam connection plate 3 d model,import the Autoform software,generate longitudinal beam before the beam connection plate finite element analysis model,to carry on the grid,set the pressure surface and the process added.Set up to simulate the stamping process of longitudinal beam before the beam connection plate,analyzed the four factors: the friction,blank holder force,punch velocity and mold clearance on stamping process and the effect of thinning area to get the parts,by the method of orthogonal experiment,the levels of four factors are combined test analysis,get the optimal combination of the parameters,die clearanceof 1.25 mm,0.15 friction coefficient,blank-holder force 440 kn,stamping speed 0.85 m/s.According to the combination process parameters obtained by orthogonal test,the die design and test verification were carried out.Trials according to the result of orthogonal experiment set mold clearance,reduce the surface roughness of the mold cavity and sufficient lubrication,and adjust the blank-holder force and stamping speed,test results show that the product of thinning rate down to 17.5%.The production quality and efficiency of the front girder joint plate are improved.The results of simulation analysis,test results and test process of this paper have certain reference value for stamping production of other similar parts.