第42卷第4期 Vol. 42No. 4
假压技术
FORGING & STAMPING TECHNOLOGY
汽车纵梁冲压成形数值模拟及试验验证
毛卫国
（上汽通用五菱汽车股份有限公司，广西柳州545005）
2017年4月 Apr.2017
摘要：利用有限元模拟软件Autofom对汽车纵梁进行成形性分析，拟定落料一→弯曲一切边、侧冲孔一翻边、上翻边侧整形一切边、冲孔、侧切边、侧冲孔的工艺路线，并对回弹趋势进行预测。分析表明：当压边力增大到1500kN时，纵梁尾部回弹减少到1.75mm，即通过增加压边力可提高零件塑性变形的程度从面减少回弹。经过实际验证，数值模拟结果对起皱等缺陷的位置和大小预测较为准确；数值模拟可对回弹进行定性预测，利用其结果进行修正后反复模拟，可将回弹量由首次预测的13mm缩减到最终的2mm，再通过测量实际零件的回弹量并结合数值模拟结果进行补偿和修正，可进一步提高零件尺寸精度。
关键词：汽车纵梁；冲压成形；回弹；压边力；数值模拟 DOI: 10. 13330/j. issn. 1000-3940. 2017. 04. 010
中图分类号：TG386
文献标识码：A
文章编号：1000-3940（2017）04-0055-04
Numericalsimulationandexperimentalverificationonstamping
formabilityforautomobilecrossbeam
Mao Weiguo
(SAIC GM Wuling Automobile Co., Lid., Liuzhou 545005, China)
Abstract: The formability of automobile crossbeam was simulated by finite element modeling software Autoform. Then, the process route of blanking → bending →/ trimming, side piercing →/ flanging, up flanging → side sizing → cutting, piercing, side cutting, side piercing was designed, and the trend of springback was predicted. The results show that the springback at tail end of crossbeam reduces to 1. 75 mm when the blank holder force increases to 1500 kN, that is to see that the plastic forming is improved and the springhack is de-duced by increasing blank holder force. The simulation result which verified by experiment indicates that the prediction of defect position of wrinkle as well as range is accurate. Then, the springback can be predicted qualitatively by numerical simulation, and the modified re sult is re-simulated over and over again. Therefore, the springback can be reduced from 13 mm to 2 mm. The springback obtained by practical part measurement is compensated and modified by combining with its numerical simulation result, and the part dimension accura cy can be improved.
Key words : automobile erossbeam; stamping forming; springhack ; blank holder foree; numerical simulation
汽车纵梁是底盘系统的关键零件，其精度的高低直接影响整个下车体的匹配质量。但是，由于其结构形状复杂，在成形过程中往往容易出现回弹、翘曲等问题，导致零件精度降低，给整车匹配带来不利影响(1-2)。近年来，为了满足燃油经济性要求，汽车零部件轻量化的趋势日益明显，各种高强度、超高强度钢被广泛应用以满足这些需求。而目前正在开发的第3代高强度钢板，强度甚至达到或超过
收稿日期：20161124；修订日期：20170210 基金项目：国家重点研发计划（2016YFB0300405）作者简介：毛卫国（1971-），男，学士，工程师
E-mail: weigua. mao@ sgmw. com cn 万方数据
1500MPa(3-6)。由于材料强度的不断提高，回弹、翘曲成为汽车纵梁零件冲压过程中的主要难题。
而通过传统的试错方法对回弹进行整改，往往需要在模具加工完成后，通过测量实际零件偏差，再进行多轮调试才能得到合格零件。这种方法既增加成本，又延长模具开发时间，不利于新车型的快速开发和导人市场。因此，采用数值模拟的方法，对汽车纵梁等关键匹配零件的回弹进行分析，为补偿方案提供依据，对于提高整个车架的尺寸精度和零件质量，具有重要意义。
1
工艺分析
对于汽车纵梁类零件，一般有两条工艺路线，