Journal of Jilin University(Engineering and Technology Edition) ›› 2020, Vol. 50 ›› Issue (2): 504-511.doi: 10.13229/j.cnki.jdxbgxb20181255

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Simulation of stamping process of some reinforcement plate below windows of railway vehicles

Zheng-wei GU1(),Lin CHEN1,Li-hui ZHAO1,Hong XU1,Xin LI1,Ge YU1,2()   

  1. 1.College of Materials Science and Engineering，Jilin University，Changchun 130022，China
    2.Roll Forging Institute, Jilin University, Changchun 130022，China
  • Received:2018-12-21 Online:2020-03-01 Published:2020-03-08
  • Contact: Ge YU E-mail:gzweii@163.com;yuge@jlu.edu.cn

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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

CLC Number: 

  • TG386

Fig.1

Models of top surface of stiffening plate"

Fig.2

Uniaxial tension test"

Table 1

Stamping center and direction"

坐标轴冲压中心/mm冲压方向/(°)
x4 60084
y1 480-180
z1 630-90

Fig.3

Dieface for drawing"

Fig.4

Finite element model for tool"

Fig.5

Wrinkle and scrapping defects after drawing based on initial conditions of forming test"

Fig.6

FLD of drawing process befor touching 2 mm after assigning corner drawbead"

Table 2

Distribution of orthogonal experiment factors"

水平影响因素
AB/kNC/mm

1

2

3

0.25

0.35

0.45

600

800

1 000

0.10

0.15

0.20

Table 3

Orthogonal experiment table"

序列影响因素
AB/kNC/mm

1

2

3

4

5

6

7

8

9

A1(0.25)

A1(0.25)

A1(0.25)

A2(0.35)

A2(0.35)

A2(0.35)

A3(0.45)

A3(0.45)

A3(0.45)

B1(600)

B2(800)

B3(1 000)

B1(600)

B2(800)

B3(1 000)

B1(600)

B2(800)

B3(1 000)

C1(0.10)

C2(0.15)

C3(0.20)

C2(0.15)

C3(0.20)

C1(0.10)

C3(0.20)

C1(0.10)

C2(0.15)

Table 4

Orthogonal experiment result"

序列影响因素

最大

减薄

边角

起皱

拉延

不足

ABC

1

2

3

4

5

6

7

8

9

A1

A1

A1

A2

A2

A2

A3

A3

A3

B1

B2

B3

B1

B2

B3

B1

B2

B3

C1

C2

C3

C2

C3

C1

C3

C1

C2

0.246

0.253

0.260

0.282

0.288

0.295

0.312

0.319

0.325

严重

严重

轻微

无

无

无

无

无

无

严重

严重

轻微

正常

正常

正常

正常

正常

正常

Fig.7

Measure of thinning ratio at risk of crack"

Table 5

Analysis of orthogonal experiment result of maximum of mechanical thinning"

参数影响因素
ABC

Mi1

Mi2

Mi3

mi1

mi2

mi3

R

0.759

0.865

0.956

0.253

0.288

0.319

0.066

0.840

0.860

0.880

0.280

0.289

0.293

0.013

0.860

0.860

0.860

0.000

0.000

0.000

0.000

各因素影响度A>B>C

Fig.8

Simulation result of most optimal A2B2C3"

Fig.9

Springback compensation of dieface"

Fig.10

Evolution of spingback numeric with compensation coefficient"

Fig.11

Forming experiment"

Fig.12

Product of experiment experiment"

Fig.13

Detection of contour accuracy for reinforcement plate"

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