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外文翻译--汽车后底板的冲压模具设计分析 英文版.pdf

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外文翻译--汽车后底板的冲压模具设计分析 英文版.pdf

ELSEVIERJOURNALOFMATERIALSPROCESSINGTECHNOLOGY551995408416MATERIALSPROCESSINGTECHNOLOGYANALYSISOFDIEDESIGNSFORTHESTAMPINGOFANAUTOMOBILEREARFLOORPANELFUHKUOCHEN,JIAHONGLIUDEPARTMENTOFMECHANICALENGINEERING,NATIONALTAIWANUNIVERSI,TAIPEI,TAIWAN,ROCRECEIVED10OCTOBER1994INDUSTRIALSUMMARYTHESTAMPINGPROCESSOFMANUFACTURINGAONEPIECEREARFLOORPANELOFAPASSENGERCARHASBEENINVESTIGATEDINTHEPRESENTSTUDYANANALYSISOFTHEORIGINALDIEDESIGN,INWHICHASPLITDEFECTOCCURREDATTHEDRAWNCUPWALL,WASPERFORMEDUSINGCIRCLEGRIDANALYSISASWELLASTHE3DFINITEELEMENTMETHODTHESPLITDEFECTISDUETOTHELARGEAREAOFSHEETMETALUNDERTHEBLANKHOLDERTHATLIMITSTHEFLOWOFTHEMETALTOWARDSTHECUPAREAANOPTIMUMDIEDESIGN,WHICHCONSISTSOFASEPARATEDIEFACEANDAWEDGEMECHANISMMOUNTEDINTHELOWERDIEFRAME,WASPROPOSEDTOPROVIDEADDITIONALMETALFORTHECUPAREAANDTOELIMINATETHESPLITDEFECTWITHOUTADDINGANEXTRAOPERATIONTHISOPTIMUMDIEDESIGNWASVALIDATEDBYTHERESULTSOFCIRCLEGRIDANALYSISPERFORMEDFORTHEFIRSTANDSECONDDRAWOPERATIONSANDALSOBYTHEGOODQUALITYPANELSPRODUCEDKEYWORDSSTAMPINGDIES;REARFLOORPANEL;SPLITS;CIRCLEGRIDANALYSIS1INTRODUCTIONSPLITSAREAMONGSTTHEMAJORDEFECTSOCCURRINGCOMMONLYINTHESTAMPINGPROCESSALOTOFRESEARCHEFFORTHASBEENMADETOINVESTIGATETHECAUSESOFANDSOLUTIONSTOTHESPLITPROBLEMDURINGTHELASTFEWDECADES\14\,THEMETHODSUSEDINCLUDINGFORMINGLIMITANALYSISANDTHEFINITEELEMENTMETHODSINCEKEELERANDBACKOFEN\5\FIRSTINTRODUCEDTHECONCEPTOFFORMINGLIMITDIAGRAMSFLDSIN1963,THEYHAVEBEENUSEDWIDELYINTHEANALYSISOFSHEETMETALFORMINGINPRESSSHOPSTHEFLDSINDICATETHESTRAINSWHICHLEADTOFAILUREANDTHUSPROVIDEAUSEFULTOOLTODETERMINEIFTHEFORMINGPROCESSISLIKELYTOBEPRONETOSPLITTING,WHILSTTHEFINITEELEMENTMETHODCANCALCULATETHESTRAINDISTRIBUTIONSINTHESTAMPEDPARTSACCURATELYANDTHUSPREDICTIFTHESPLITDEFECTISLIKELYTOOCCURINGENERAL,THESOLUTIONTOPROBLEMSOFSPLITTINGISTOPROVIDEMOREMETALTOTHECRITICALAREABEFORETHEMAJORDRAWINGPROCESSSTARTSTHISCANBEACHIEVEDEITHERBYDECREASINGTHEBLANKHOLDERPRESSUREORIMPROVINGTHELUBRICATIONCONDITIONS,BUTTHEMOSTSTRAIGHTFORWARDMETHODISTOADDANEXTRAOPERATIONSOLELYFORTHEPURPOSEOFFEEDINGMOREMETALINTOTHECRITICALAREACORRESPONDINGAUTHOR09240136/96/15001996ELSEVIERSCIENCESAALLRIGHTSRESERVEDSSDI092401369502038NHOWEVER,THEEXTRAOPERATIONINCREASESTHEPRODUCTIONCOSTBYADDINGONEMORESETOFDIESANDADDITIONALMANPOWER;ANDHENCEINREALITY,ITSHOULDBEAVOIDEDINTHEPRESENTSTUDY,ANOPTIMUMDIEDESIGNINWHICHASEPARATEDIEFACEANDAWEDGEMECHANISMMOUNTEDINTHELOWERDIEFRAMEISPROPOSEDTOELIMINATETHEOCCURRENCEOFASPLITDEFECTINTHESTAMPINGPROCESSFORAONEPIECEFLOORPANELOFAPASSENGERCARTHESPECIALDIEFACEANDWEDGEMECHANISMWEREDESIGNEDTOPROVIDEADDITIONALMETALFORTHECRITICALAREAWHERETHESPLITDEFECTOCCURRED,WITHOUTADDINGANEXTRAOPERATIONBOTHCIRCLEGRIDANALYSISAND3DFINITEELEMENTSIMULATIONSWEREPERFORMEDTOANALYZETHISSPLITDEFECT2PROBLEMDESCRIPTIONTHECOMMONDESIGNFORAREARFLOORPANELOFAPASSENGERCARISUSUALLYATWOPIECETYPE,NAMELY,WELDINGTWOSTAMPEDPIECESTOGETHER,ASSHOWNINFIG1THETWOPIECETYPEDESIGNISCHOSENMAINLYDUETOTHEDIFFICULTYENCOUNTEREDINSTAMPINGAONEPIECEREARFLOORPANEL,INWHICHASPLITTENDSTOTAKEPLACEATTHEWALLOFTHEDEEPLYDRAWNCUPUSEDFORSTORINGTHESPARETIRE,ASSHOWNINFIG2THEOCCURRENCEOFTHESPLITISATTRIBUTEDTOTHESUBSTANTIALDISTANCEBETWEENTHECUPWALLANDONESIDEOFTHEBLANKHOLDER,ASSHOWNBYLINEABINFIG3,THATFKCHEN,JHLIU/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY551995408416409FIG1ATWOPIECEREARFLOORPANELSPLITFIG2ASPLITOCCURRINGATTHECUPWALLFIG3THELOCATIONOFTHEDRAWNCUPINTHESHEETBLANKRESTRICTSTHEMETALUNDERTHEBLANKHOLDERFROMFLOWINGINTOTHECUPAREAWHILSTINTHETWOPIECEDESIGNTHISDISTANCEISMUCHSHORTERANDSUFFICIENTMETALCANFLOWEASILYINTOTHECUPTOPREVENTTHEEDGEOFTHECUPFROMSPLITTING,DUETOCOSTEFFECTIVECONSIDERATIONS,AONEPIECEREARFLOORPANELISALWAYSDESIRED,SOTHATTHESPLITPROBLEMMUSTTHEREFOREBEOVERCOMETHEORIGINALPROCEDUREINTHEPRESSSHOPFORTHEPRODUCTIONOFTHEONEPIECEREARFLOORPANELCONSISTSOFFOUROPERATIONSFIRSTDRAW,SECONDDRAW,TRIMMING,ANDFLANGINGTHEFIRSTDRAWOPERATIONWASDESIGNEDONLYTOPRODUCEACUPSHAPE,ASSHOWNINFIG3ASTORTHERIBSAROUNDTHECUP,THESEWEREFORMEDINTHESECONDDRAWOPERATIONLIKEMOSTSTAMPINGPROCESSES,THEMAINDEFORMATIONOFTHEREARFLOORPANELISCOMPLETEDINTHEFIRSTDRAWOPERATIONTHECONVENTIONALDRAWPROCESSALLOWSTHEPUNCHTOPULLMOREMETALINTOTHEDIECAVITYFROMTHEBLANKHOLDERTOFACILITATEMETALFLOW,NODRAWBEADSWEREEMPLOYEDONTHEBLANKHOLDERSURFACEHOWEVER,DUETOTHELARGEDRAWDEPTHANDTHEGEOMETRICDIFFICULTYMENTIONEDABOVE,ASPLITWASSTILLFOUNDATTHECUPWALLNEARTHEBOTTOMAFTERTHEFIRSTDRAWOPERATION,ASSHOWNINFIG2THELOCATIONOFTHESPLITDEFECTINDICATESTHATTHECONSIDERABLEDISTANCEBETWEENONESIDEOFTHECUPWALLANDTHEBLANKHOLDERDOESPREVENTTHEMETALFROMFLOWINGTOWARDSTHECUPSOMEEFFORTSHAVEBEENMADETOHELPTHEMETALTOFLOWTOWARDTHECUPAREATHE,ATTEMPTOFDECREASINGTHEBLANKHOLDERPRESSURELEDTOMOREWRINKLESATTHEROOTOFTHECUPAREABUTWITHOUTELIMINATINGTHESPLITIMPROVEMENTOFTHESHEETMETALQUALITYWASALSOPROVENTOBEINVAINEXTREMECARETAKENWITHTHELUBRICATIONCONDITIONSCANEASETHESPLITPROBLEMHOWEVER,THISISNOTCOSTEFFECTIVEFORTHEPROCESSOFMASSPRODUCTIONALSOTHELARGEQUANTITYOFLUBRICATIONOILUSEDINTHESTAMPINGPROCESSMAYPOLLUTETHESHOPFLOORHENCE,THEMOSTEFFICIENTWAYLEFTTOSOLVETHISPROBLEMISTOPROVIDEMOREMETALFORTHECUPAREABEFORETHEPUNC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