Determination Of Formability Parameters Of DC05 Sheet And Optimization Of Stamping Process For Automobile Seat Support Plate

In recent years,with the introduction of foreign automotive technology,China automobile industry is also facing fierce market competition while developing rapidly.The traditional cover mold design method can no longer meet the needs of the development of the automotive industry.The use of numerical simulation to guide the stamping process design can effectively shorten the development cycle of the cover mold and improve the competitiveness of automobile enterprise.However,the default materials in the numerical simulation software and the materials actually used for stamping have some differences in the formability parameters,and forming defects of the parts cannot be accurately predicted.Therefore,this paper obtained the formability parameters by measuring the DC05 sheet and applied it to the numerical simulation of a car seat support plate.Then,based on those,the process optimization and experimental verification of the part was carried out.The specific research contents are as follows:(1)Select the DC05 sheet used to produce the car seat support plate,and perform the uniaxial tensile test at different strain rates for samples with different cutting directions to obtain the formability parameters of the sheet: tensile strength ?b,Yield strength ?s,elongation ?u,strain hardening index n,thick anisotropy coefficient r and hardening coefficient K;the forming limit curve of the sheet was obtained by the Argus optical measuring system through bulging experiment of DC05 sheet at room temperature.(2)Process analysis of the car seat support plate was made to determine the part stamping process plan.The initial simulation analysis of the process scheme was carried out using Autoform default material parameters and experimental determination of material parameters.Comparing the forming results of the drawn and final parts,it was found that the material simulation can accurately predict the forming defects of the parts during the stamping process.(3)For the wrinkles and cracking defects existing in the drawn parts,the wrinkle defects of the drawn parts are solved and the cracking defects are alleviated at the same time by optimizing the draw-bead and binder surface.Then,with the maximum thinning,maximum thickening and safe area ratio as the optimization target,the blanking force and the three-component section draw-bead were selected as the design variables,and the 4-factor 3-level orthogonal test was carried out to obtain optimum process parameters and successfully eliminate the cracking defects of the drawn parts.(4)For the cracking and wrinkling defects of the flanging and restriking parts,the flanging forming defects of the workpiece were successfully solved by reducing the radius of the flanging fillet and adjusting the punching direction.Finally,the actual punching test was carried out on the part,and the formed part was tested to examined the product quality requirements.