轨道车辆窗下补强板冲压成形模拟

doi:10.13229/j.cnki.jdxbgxb20181255

摘要/Abstract

摘要：

以某款地铁车辆窗下补强板为例，利用有限元软件Autoform，研究了拉延筋强度系数、压边力和模具间隙参数对补强板件成形的影响。结果表明：拉延件拉裂主要由成形过程中板料局部流动不均匀所致，起皱是由于拉延过程中边角处物料聚集引起；拐角处设置重拉延筋可极大地消除起皱缺陷，通过正交试验找出参数匹配的最优组合，可进一步对边角起皱和拉裂缺陷协调控制。最优参数组合是拉延筋强度系数为0.35、压边力为800 kN和单边模具间隙为0.20 mm；基于回弹量对模具型面进行补偿可有效控制轮廓精度，取1.1的补偿系数时效果最好。基于模拟结果进行了成形试验，得到了合格工件，验证了模拟控制措施的有效性。

关键词: 金属学与金属工艺, 拉裂, 回弹控制, 轨道车辆窗下补强板, 数值模拟

Abstract:

The forming process of some reinforcement plates below the windows of railway vehicles was stimulated and analyzed using the general finite element software Autoform. The influences of the process parameters such as drawbead, blankholder force and die-clearance were investigated. The results show that the split defect of sheet is caused by uneven material flow, and the wrinkle defect is caused by the assembly of materials in corners, which can be eliminated through decorating additional drawbeads in the corners. The optimal combination of parameters was found by orthogonal experiments, which could further control the split and the wrinkle defects. The optimized parameters are force factor of drawbead 0.35, constant force of the blankholder 800 kN and the single-side die clearance 0.20 mm. Compensation to the die face based on springback can significantly control the contour accuracy. The most optimal coefficient is 1.1 times of the springback amount. Forming experiments were conducted according to the simulation results and the qualified product was obtained, which proves validity of the proposed defect controlling methods.

Key words: metal science and metal technics, split, springback control, reinforcement plate below the windows of railway vehicles, numerical simulation

中图分类号:

TG386

谷诤巍,陈琳,赵立辉,徐虹,李欣,于歌. 轨道车辆窗下补强板冲压成形模拟[J]. 吉林大学学报(工学版), 2020, 50(2): 504-511.

Zheng-wei GU,Lin CHEN,Li-hui ZHAO,Hong XU,Xin LI,Ge YU. Simulation of stamping process of some reinforcement plate below windows of railway vehicles[J]. Journal of Jilin University(Engineering and Technology Edition), 2020, 50(2): 504-511.

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坐标轴	冲压中心/mm	冲压方向/(°)
x	4 600	84
y	1 480	-180
z	1 630	-90