汽车后车门成型工艺与模具设计【机械类毕业-含CAD图纸】
收藏
资源目录
压缩包内文档预览：(预览前20页/共27页)
编号：12131683
类型：共享资源
大小：5.34MB
格式：ZIP
上传时间：2018-12-25
上传人：小***
认证信息
个人认证
林**（实名认证）
福建
IP属地：福建
100
积分
- 关 键 词：
-
机械类毕业-含CAD图纸
汽车
车门
成型
工艺
模具设计
机械类
毕业
cad
图纸
- 资源描述：
-
汽车后车门成型工艺与模具设计【机械类毕业-含CAD图纸】,机械类毕业-含CAD图纸,汽车,车门,成型,工艺,模具设计,机械类,毕业,cad,图纸
- 内容简介：
-
译文题目： Draw-in map for stamping die tryout 在地图绘制冲压模具的试模 外文Title:Draw-in map for stamping die tryout United States Patent 7130708Abstract: Sheet metal forming is a manufacturing process in which flat sheet metal is drawn into a die cavity to form a product shape. Draw-in amount is the single most important stamping index that controls all forming characteristics (strains and stresses), formability failures (splits, wrinkles) and surface quality (distortions) on a panel. Adaptation of a new die set for repetitively stamping sheet metal parts to a part design specification is simplified by using a math-based simulation of the stamping operation under specified engineering stamping conditions for the specified part. The stamping simulations are used to create an engineered draw-in map comparing selected locations on the peripheral edge of the stamped part with corresponding locations on the peripheral edge of its original sheet metal blank. The resulting map of sheet metal draw-in dimensions reflect suitable displacements of the metal sheet between the binder ring and binder surface of the female die member at all such locations as the punch member of the die set executes its stamping operation. The engineered draw-in dimensions for a simulated part identify specific locations for adjustment of the binder ring/binder surface system in adapting the die set for production of parts.Inventors:Wang, Chuan-tao (Troy, MI, US)Goan, Norman (Troy, MI, US)Zhang, Jimmy J. (Troy, MI, US)Application Number:10/404728Publication Date:10/31/2006Filing Date:04/01/2003Export Citation:Click for automatic bibliography generationAssignee:General Motors Corporation (Detroit, MI, US)Primary Class:700/111Other Classes:700/30, 700/109, 700/117International Classes:G06F19/00;B21D37/20;G06G7/48Field of Search:72/379.2, 700/30, 700/193, 700/110, 700/182, 72/17.3, 700/111, 700/174, 72/362, 700/97, 700/108, 700/117, 700/176, 700/118, 700/98, 700/109, 700/95View Patent Images:Download PDF 7130708 PDF helpUS Patent References:6769280Real-time draw-in sensors and methods of fabrication2004-08-03Cao et al.72/17.320030167097Method for the designing of tools2003-09-04Hillmann et al.700/9820020186007Real-time draw-in sensors and methods of fabrication2002-12-12Cao et al.5974847Superplastic forming process1999-11-02Saunders et al.72/57Primary Examiner:Picard, LeoAssistant Examiner:Kasenge, CharlesAttorney, Agent or Firm:Hargitt, Laura C.Claims:The invention claimed is:1. A method of adapting a sheet metal forming die set to repetitively make a specified formed sheet metal part having a formed part peripheral edge from a sheet metal blank having a sheet metal blank peripheral edge; said die set comprising a die cavity member with a sheet metal blank binder surface and a binder ring for pressing said blank against said binder surface, said binder surface and binder ring comprising bead and trough surfaces for controlling draw-in of sheet material of said blank into said die cavity during forming of said sheet metal part, said method comprising: producing a computer simulation of the forming of said part under predetermined engineered forming conditions using a simulation of said die set to obtain a data set of simulated draw-in dimensions of locations on said formed part peripheral edge with respect to corresponding locations on said sheet metal blank peripheral edge; making a draw-in map of said simulated draw-in dimensions; and comparing said simulated draw-in dimensions of said map with corresponding draw-in dimensions obtained on a trial sheet metal part formed on said sheet metal forming die set for use in adapting said die set for the repetitive stamping of said specified part.2. A method as recited in claim 1 comprising: forming a trial part on said sheet metal forming die set under said predetermined engineered forming conditions; measuring draw-in dimensions of said peripheral edge of said trial part at locations corresponding to draw-in dimensions of said map; comparing said draw-in dimensions of said map with corresponding draw-in dimensions for said trial sheet metal part; identifying any location on said peripheral edge of said trial part at which a draw-in dimension differs from said map; and altering said bead and/or trough surfaces to change said draw-in of sheet metal to reduce said difference in draw-in dimension.3. A method as recited in claim 2 comprising changing the shape of said bead and/or trough surfaces at a location corresponding to said location on said peripheral edge of said trial part to change said draw-in of sheet metal.4. A method as recited in claim 2 comprising repeating the steps of claim 2 until said die set can repetitively make said specified sheet metal part.5. A method as recited in claim 3 comprising repeating the steps of claim 3 until said die set can repetitively make said specified sheet metal part.6. A method of trying out a sheet metal forming die set to adapt it to repetitively make a specified formed sheet metal part having a formed part peripheral edge from a sheet metal blank having a sheet metal blank peripheral edge; said die set comprising a male punch die member, a female die cavity member with a sheet metal blank binder surface, and a binder ring for pressing said blank against said binder surface, said binder surface and binder ring comprising complementary bead ring and trough surfaces for controlling draw-in of sheet material of said blank into said die cavity during a forming movement of said punch, said method comprising: producing a computer simulation of the forming of said part under predetermined engineered forming conditions using a simulation of said die set to obtain a data set of simulated linear draw-in dimensions at locations around the peripheral edge of said specified formed part with respect to corresponding locations on said sheet metal blank peripheral edge; making a draw-in map of said simulated linear draw-in dimensions; forming a trial part on said sheet metal forming die set under said predetermined engineered forming conditions; measuring draw-in dimensions for the peripheral edge of said trial part at locations corresponding to draw-in dimensions of said map; comparing said draw-in dimensions of said map with corresponding draw-in dimensions for said trial sheet metal part; identifying any location on the peripheral edge of said trial part at which a draw-in dimension differs from said map; and altering said bead ring and/or trough surfaces to change said draw-in of sheet metal to reduce said difference in draw-in dimension.7. A method as recited in claim 6 comprising altering said bead ring and/or trough surfaces at a location corresponding to said location on said peripheral edge of said trial part.8. A method as recited in claim 6 in which said forming movement of said punch comprises a movement from a point of first engagement of said sheet metal blank to a final forming point in which said blank has been pushed into conformance with said die cavity member, said method comprising: producing said computer simulation of the forming of said part when said punch is at said final forming point, and forming said trial part to said final forming point.9. A method as recited in claim 6 in which said forming movement of said punch comprises a movement from a point of first engagement of said sheet metal blank to a final forming point in which said blank has been pushed into conformance with said die cavity member, said method comprising: producing said computer simulation of the forming of said part when said punch is at an intermediate forming point between said point of first engagement and said final forming point, and forming said trial part to said intermediate forming point.10. A method as recited in claim 6 comprising repeating said forming, measuring, comparing, identifying and altering steps until said die set can repetitively make said specified sheet metal part.11. A method as recited in claim 7 comprising repeating said forming, measuring, comparing, identifying and altering steps until said die set can repetitively make said specified sheet metal part.12. A method as recited in claim 8 comprising repeating said forming, measuring, comparing, identifying and altering steps until said die set can repetitively make said specified sheet metal part.Description:TECHNICAL FIELD This invention pertains to sheet metal formability and die making, and to methods for tryout of dies for sheet metal forming. More specifically, this invention relates to the use of a map of sheet metal draw-in or displacement distances around the periphery of a stamped sheet metal part in math-guided tryout of a three or four component die set comprising a punch, binder ring(s) and female die designed for making the part.BACKGROUND OF THE INVENTION A conventional three-component die set for stamping sheet metal parts consists of a punch, a binder ring and a female die. Such die sets are used to make many strong and light weight articles of manufacture. These articles include, for example, automotive body panels and other structure parts; aircraft and appliance sheet components; and beverage cans. Families of formable ferrous and aluminum sheet metal alloys have been developed for these manufacturing processes.In a typical sheet metal forming operation, a flat blank of the metal is held at its periphery over the shaped cavity surface of a female die and the sheet is pulled into the cavity and against the shaped surface using a punch with a forming surface complementary to that of the female die. The sheet is drawn and stretched between the tools and assumes a desired shape. In making stamped parts such as automotive body panels, often characterized by deep pockets and small radii bends, the panel may be formed in stages using two or more sets of stamping dies each operated in a suitable hydraulic press.In sheet metal stamping operations the blank is clamped at its periphery against the marginal surface of the female die cavity with a blank holder called the binder ring. The interaction between the binder ring, the interposed sheet and the binder portion at the margin of the female die is critical to making a part that is formed free of wrinkles or tears. The binder ring has a bead that presses adjacent sheet metal into a complementary depression, a trough, in the binder portion of the female die to create proper restraining forces that prevent the sheet metal from being drawn to the die cavity too freely (and cause wrinkles on the sheet metal) or too restrictively (thus causing panel splits). Thus, a peripheral ring of the blank material is crimped and grasped by the binder ring system. When operation of the stamping press brings the punch into contact with the blank, the metal sheet is drawn and/or stretched into the forming cavity. The binder bead/trough interactions at each point around the entire periphery of the blank control the local amount of sheet metal drawn into the forming die. The draw-in of too little metal over the binder ring system can lead to tears or cracks in the stamped part, and too much drawn metal can lead to wrinkles and surface distortions. The draw-in amount is controlled by the die design and die construction, the forming process parameters (binder force, lubrication, die set-up), and the sheet metal properties.In a traditional die development and making process, a die is designed based on previous experience, and the die is validated through a series of physical tryouts. These tryouts are time consuming and costly and cannot guarantee the success of the die developments. For a typical automotive body panel, say a fender, the tryout alone could last twelve months and cost more than one million U.S. dollars. Today in math-based die development practice, the design of a die can be evaluated and reshaped through electronic tryout via advanced stamping simulation technology that consists of stamping CAE (computer aided engineering) programs, sheet metal forming simulation software (e.g., Pamstamp and Dyna3D) and high performance computers.After the die sets for a vehicle body panel, for example, are designed or developed successfully in the digital world, the dies are constructed and tried out in a tooling shop. However, there are differences between the engineering of a die set and its everyday use in a manufacturing operation. And there are differences in results obtained between digital simulation of die operation and physical parts produced in a stamping plant. One aspect of the problem is that die makers are not so familiar with math-based die engineering principles that they can make good use of the math-based work in tuning actual dies for everyday stamping operations and ordinary sheet metal material. Therefore, physical tryout periods for each set of manufacturing dies can still take weeks or months because there has been no robust procedure by which manufacturing people can detect and correct differences between an actual die set and the math-based simulation from which it was built.It is an object of this invention to provide a process for conforming actual sheet metal stamping experience using a specific die set with state-of-the-art math-based simulation of the die set and stamping operation. It is a more specific object of this invention to provide a process for using the exact amount of sheet metal drawn in over the binder ring at selected locations around the periphery of the blank as a practical and effective basis to conform the operation of the physical die set to the simulated performance of the virtual die set.SUMMARY OF THE INVENTIONThis invention makes use of the capabilities of current mathematically based, computer executed sheet metal forming technology to produce a data set that can be used by stamping die tryout workers to rapidly produce defect free stamped parts using the stamping die set. This invention is a process that is based on the premise that the amount of sheet metal blank that is drawn into the die cavity is a critical manufacturing index that suitably reflects actual strains, stresses and thinning experienced by the stamped metal. It is perceived that the amount of draw-in can be used to anticipate stamping failures and that controlling the amount of draw-in at selected locations around the periphery of the blank is a simplest and robust way for die makers on the shop floors to tune the die set to make good stampings with a maximum efficiency and minimum efforts and costs.In accordance with the practice of the invention, the math-based process is used to simulate the stamping of the part using the stamping die set made in accordance with the die design specified by the computer process. The math-based process is used to predict the sheet metal draw-in amount at sheet metal strain and stress levels throughout the stamping stroke of the punch that produce a defect free part. The mathematical simulation takes into account specified engineering die tryout conditions. These conditions include the material specification of the blank and its mechanical properties such as yield strength, ultimate tensile strength and coefficient of friction. The engineered die tryout conditions also include the thickness and shape (geometry) of the blank, the amount of binder travel, binder force (tonnage), forming tonnage, male bead and female bead (trough) configuration, lubrication, and the like. An engineered draw-in map is prepared comparing the periphery of the original blank with the shrunken periphery of the part as formed in the computer simulation. The draw-in map shows the linear dimensions in, e.g., millimeters, at locations around the plan view of the part of the draw-in of the sheet from the flat blank to the formed panel. In addition, like draw-in maps can be prepared at intermediate part forming stages based, e.g., on the apparent travel of the punch from initial contact with the blank to the completion of the die set forming stroke.Die tryout workers can use the engineered draw-in map as a basis for correcting actual draw-in of the blank on the real die set. Where the sheet metal draw-in distance on the trial part is larger or smaller than the map dimensions suitable compensation adjustments are made to the bead shapes to reduce or increase sheet metal flow. Invariably, as the actual draw-in values around the periphery of formed parts are brought into conformity with the simulated stamping draw-in values, good parts are produced.The advantage of this invention is that die tryout workers can focus on draw-in of the sheet metal as the part is formed, one of the occurrences that they regularly observe in the making of each stamping. Now, with the use of the engineered draw-in map, die tryout workers can more efficiently approach the die tryout process by conforming actual sheet metal draw-in dimensions with the math based simulation draw-in map and, where necessary, making adjustments to the beads at specific locations identified from the draw-in map.Other objects and advantages of the invention will become apparent from a detailed description of a preferred embodiment of the draw-in map process.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is an exploded view of the forming surfaces of a three-piece die for forming a vehicle fender panel. The figure comprises, from top to bottom, the forming and peripheral surface of the female die, the sheet metal blank, the binder ring surface, and the punch forming surface.FIG. 2 is an enlarged sectional view of a broken out portion of FIG. 1 showing the male bead on the binder ring and the bead trough on the peripheral surface of the female die with the interposed blank and underlying punch surface.FIG. 3 is a plan view of the precut blank for forming the fender panel.FIG. 4 is a plan view of the formed fender panel including a draw-in map. Drawn around the perimeter of the illustrated, formed sheet meal part is the outline of the original blank. Also marked around the perimeter of the original blank are directional arrows of the sheet metal draw-in and dimensions in millimeters of the amount of metal draw-in for a suitably formed fender panel.FIGS. 5A5D are a series of four cross-sectional views (section5A5A of FIG. 4) of the position of the punch, binder ring, sheet metal blank and female die surface at progressive stages of the forming operation. In this example the press moves the female die surface downwardly pushing the blank against the binder ring and punch forming surface.FIG. 5A schematically shows the position of the die components as the binder ring has wrapped the blank against the female die surface, and the punch is first touching the surface of the secured blank. In this example, the punch is 137 millimeters from the completion of the die set forming stroke.FIG. 5B shows the position of the die components and sheet metal when the punch has advanced to a position 73 millimeters from the completion of the die set forming stroke.FIG. 5C shows the position of the die components and sheet metal when the punch is 19 mm from the completion of the die set forming stroke.FIG. 5D shows the completion of the forming stroke of the die set.DESCRIPTION OF THE PREFERRED EMBODIMENTThe practice of the invention is illustrated in connection with the stamping of an automotive vehicle fender outer panel. The fender panel may be stamped using a suitable low carbon steel metal blank or aluminum alloy blank, or the like. A shape for the fender is conceived by automotive designers. The design is transcribed into mathematically based dimensional and spatially locating data for use in computer assisted engineering design of a die set for the stamping of the fender panel. Commercially available computer based programs such as those identified above are used to then design a female die surface and a male punch surface and a binder ring shape suitable for controlling the stamping of the selected sheet metal material. Data concerning the thickness of the sheet metal, its physical properties and its deformation forming characteristics are used in the computer program in the design of the die set. Some panel shapes may require more than one stamping operation and, thus, more than one set of stamping dies to make the part.The die components of a set are then made by known practices and as soon as they have been finish machined or otherwise shaped to the specification of the math based program, the components are ready for try-out with an actual blank of the specified sheet metal material. FIG. 1 illustrates, in exploded view, the arrangement of the movable female forming die surface110(sometimes called the upper die surface in this specification), a sheet metal blank112, binder ring114, and a stationary male punch surface116. The full die members are not shown to simplify the illustration.The female die member is secured in the upper platen of a suitable stamping press. The press is of known design and is also not shown to simplify the illustration. In this example, the female die surface110is movable. Female die surface110has a shaped cavity portion118, the surface of which is designed to shape the top surface120of blank112as the outer surface of a fender panel in a stamping operation. Female die surface110also has a peripheral surface122completely surrounding cavity portion118. During a stamping action of the press and die components, the peripheral portions of blank112are clamped against peripheral surface122of the upper die110by binder ring114.Binder ring114is also secured in the press in a manner so that it can be separately moved to clamp an inserted blank112against peripheral surface122of the upper die when the upper die110is moving downwardly with the press rams. Binder ring114is shaped to define an opening124through which the punch die member with its punch surface116can enter to push against the lower surface126(see FIG. 2) of blank112as it is moved downwardly by upper die surface110. Binder ring114also has a bead128which is illustrated in FIG. 1 as a single continuous linear raised surface like a ring around the perimeter of opening124. Bead128will typically have different cross-sectional shapes in different regions around its ring configuration, and the bead ring may be formed in discrete linear segments.The stationary punch die member, with its punch surface116, is secured to the lower platen of the press.As may be apparent from the brief description of the die components, a fender panel stamping cycle is commenced with the die component members and surfaces in their open position as shown in FIG. 1. The lower platen of the press supports punch with punch surface116in the open position of the die set. Binder ring114has been lowered to permit the insertion and precise location of blank112between the upper die surface110with peripheral surface122and binder ring bead128. In a first closing step of the press, the upper die surface110is moved down to press the blank112against binder ring114. Binder ring114engages the bottom surface126of blank112to clamp the perimeter of the blank112against the peripheral margin surface122of the upper die surface110. Bead128on the binder ring114presses the overlying blank material against upper die surface122and crimps peripheral blank material into trough130(see Figure2) formed in peripheral surface122. Trough130is shown only in a cross-section in FIG. 2. But trough130is formed in a ring-like linear path in surface122completely around the cavity surface118so that it overlies bead128. The opposing portions of the bead128and trough130cooperate in each portion of their respective rings to control the draw-in of sheet metal during stamping. As will be described further, the specific shapes and dimensions of bead128and trough130control the draw-in of the blank material when the punch surface116forces the blank112against cavity surface118.When upper die surface110is moved to press blank112and binder ring114downwardly, the stationary punch with punch forming surface116engages the lower side126of blank112and continually pushes it into the cavity of the upper die into conformance with female die surface118to thus form the fender panel sheet. In the closing operation of the press, punch surface116passes through opening124in binder ring114to draw a portion of the blank into the upper die cavity118. Of course, metal at the edge of the blank112is pulled over the bead128of binder ring114and through the trough130of upper die110around the entire, usually enclosed path, of these linear, ring-like die elements. The shapes of the bead128and trough130in combination with action of the punch and female die surfaces116,118controls whether an acceptable stamping is formed. It is the control provided by the bead and trough over the flow of blank material that largely determines whether the proper amount of metal is drawn and stretched into the female cavity.In the example illustrated in FIG. 1, a panel is fully formed from an initially flat blank114of sheet metal into the fender member. In a subsequent operation the peripheral portion of the blank that is not used in the forming of the outer fender panel is trimmed away.FIG. 2 is a somewhat enlarged view of a broken out section (at22) of the die components and blank illustrated in FIG. 1. FIG. 2 illustrates one cross-section of a bead128and trough130. As is known to die engineers, the height and width of the bead, or bead segments, and the radii of its corners are specified when the bead is formed on the surface of the binder ring (or on the surface of the upper die if the bead is formed there). Likewise, the corresponding dimensions of a trough, whether formed in the upper die or on the binder ring, are initially specified when the die set is made. However, if the initially specified shapes at mating regions of a bead or trough segment are not suitable they are changed, e.g., reduced or enlarged or provided with sharper or softer radii, during tryout of a die set.FIG. 3 is a plan view of the flat, two dimensional outline, of a sheet metal blank112for stamping a fender outer panel on the die set surfaces shown in FIGS. 1 and 2. The blank will usually be of a suitable low carbon steel or aluminum alloy composition and have a thickness of, e.g., one to three millimeters. As stated, the mechanical and formability properties of the sheet metal are known and used in the computer aided design of the members of the die set. In this example, the blank is not of simple rectangular shape. The blank is provided with a two-dimensional outline generally resembling the outline of the fender to minimize scrap. But the shape and dimensions of the sides of the blank are important in assuring that the proper amount of metal is available on all sides for draw-in to the forming cavity, e.g., cavity surface118. And provision must be made in the blank shape for suitable engagement with the binder bead128and trough130combination. Referring to FIG. 3, edge140lies at the front end of what will become the fender panel;132at the top of the intended fender;134at the rear of the fender next to a door and edges136and138at the wheel well and bottom, respectively. But the locations of these edges on the blank112are located within a millimeter of specified design for use in the draw-in map used in the practice of this invention. Furthermore, the blank112is precisely located when it is places in the press between the upper die surface110and binder ring114. For simplicity of illustration, the total perimeter of edges130138is identified as144in the draw-in map of FIG. 4.After the upper die surface110has completed its full stroke and punch116has pushed the blank material into the upper cavity against female cavity surface118, the press then reverses its motion. The upper die110is raised and the stamped part142can be removed from the punch surface116. FIG. 4 is a plan view of the stamped fender panel sheet142. Fender panel sheet142comprises the fender panel shape, corresponding to cavity surface118, plus peripheral edge material used in the stamping process.FIG. 4 is an example of an engineered draw-in map essential to the practice of this invention. The outline of the formed sheet metal142is shown in plan view FIG. 4. Also superimposed around the perimeter of the deformed sheet metal part is the perimeter144of original blank112. The perimetrical outline of formed part142is smaller than the perimetrical outline144of blank112. The sheet material of the formed part142has experienced draw-in or displacement from the outline144of the original blank112. The precise amount of draw-in varies around the respective perimeter segments depending upon local flow of the sheet material over the binder ring bead system of bead128and trough130.Also shown on FIG. 4, are several one and two digit numbers associated with directional arrows. The arrows indicate the direction of draw-in of the stamped sheet metal from the perimeter144of the original blank112. The numbers represent the dimensions, in millimeters, of the draw-in at the location of the associated arrow. The dimensions shown in FIG. 4 are dimensions determined by a math-based simulation of the fender panel sheet metal142on a die set corresponding to the try-out die set and under specified engineered tryout conditions for the stamping operation of the type listed in the Summary of Invention section of this specification. Thus, FIG. 4 represents a map of the idealized draw-in of the formed part from the original blank112shape in accordance with a math based simulation of the drawing process. Such a map may contain, for example, a draw-in dimension at points every 100 mm or so around the perimeter of the blank and formed piece. While several such draw-in dimensions are shown in FIG. 4 as many as forty or more dimensions might be mapped in a fender panel like that illustrated.In accordance with this invention, the data in the map of FIG. 4 is used to compare with the actual draw-in dimensions at corresponding locations of a trial stamped part formed during tryout of newly made tooling. The trial stamping is made under the same engineered tryout parameters or conditions as imposed on the math-based simulation. Comparison of a trial part with the engineered draw-in map identifies locations, if any, where there is a significant difference between the experienced draw-in values and math-based simulation draw-in values. It is found that the die tryout process is very effectively shortened by focusing on reducing such differences in draw-in values to match the engineered draw-in. Where the trial part has experienced a significant difference in draw-in compared to the math-based map, the male beads and/or female trough elements are altered to correct the metal flow and the altered die set given a new trial with a new blank. The general relationship between bead and trough size and radii and metal flow is known. The die tryout process is greatly shortened by using a draw-in map as the sole basis of determining alterations to the bead and trough components of a die set.The use of the math-based draw-in map can be used at intermediate stages of the stroke of the punch member of the die set. In other words, draw-in occurs progressively as the punch progressively forces the blank metal into the cavity of the female die member.FIGS. 5A5D illustrate in schematic views how sheet metal draw-in occurs progressively in the forming of the part. These Figures also illustrate a cross-sectional view (at line5A5A of FIG. 4) of a bead128and trough130combination at two locations on the die set diametrically opposed to each other in the sectional view. The bead is illustrated on the binder ring and the trough on the female die surface but these locations can be reversed. Also the press operation is illustrated with the female die being lowered toward the punch but other die set closing modes may be employed.FIG. 5A shows binder ring114clamping sheet metal blank112against the peripheral surface122of the female die surface118when the upper die moves. Punch surface116just touches the bottom surface126of blank112, but the upper die must still travel a distance of, for example, 137 mm before the die set is fully closed and the stamped metal panel142is made. Sheet metal blank112is gripped by bead128on binder ring114and trough130on die surface122around the perimeter of the sheet. The bead128and trough130are seen at both sides of the blank112in these sectional views of FIGS. 5A5D. At the position of the punch surface116shown in FIG. 5A there has been no draw-in of the blank sheet metal and there is ample blank material (some broken off in5A) outside of each bead/trough location in this section.FIG. 5B shows punch surface116after the upper die has been moved downwardly over almost half of its forming stroke. For example, it may now be considered to be a distance of 73 mm from the completion of its stroke. Blank112is being deformed upwardly toward female die surface118. Although some metal stretching occurs, this deformation is largely accommodated by blank material being drawn inwardly over bead ring128and through trough130in the female die peripheral surface122. The cross-section of the blank112illustrated in these FIGS. 5A5D experiences a significant amount of deformation and provision for adequate draw-in material must be provided. A useful math-based simulation draw-in map could be prepared for this portion of the stroke of the punch surface116. And a trial part could be prepared by programming the press to stop at this point on its stamping stroke. The draw-in dimensions of the trial part are compared with the math-based draw-in map at this stage of part-making to evaluate die performance at intermediate part formation.FIG. 5C shows the upper die surface118at a further stage of closure. For example, the upper die is now 19 mm from the completion of its forming stroke. More blank material will have been drawn between bead128and trough130. FIG. 5C further illustrates the progressive draw-in of blank metal in the stamping process. As observed with respect to FIG. 5B a math-based draw-in map can be made at any intermediate portion of the punch stroke for assessing suitable metal draw-in at that forming stage during the tryout of a die set.Finally, FIG. 5D shows the punch and punch surface116at completion of die set closure with the fender panel now formed. The operation of the die set should be such that peripheral blank material is still within the grip of the binder ring system.The practice of this invention utilizes math-based simulations to facilitate die tryout. The simulations, made under specified engineered stamping conditions, are used to predict sheet metal blank draw-in during the stamping of a specified sheet metal part. Trial parts are made under the same engineered stamping conditions and the trial part draw-in compared with a map of the math determined draw-in. Comparisons may be made with the fully formed part and at intermediate part forming stages. If the measured draw-in does not match the engineered draw-in, initial trial parts often are unsatisfactory because of defects such as wrinkles or splits or tears in the stamped metal. It is found that a most efficient way to correct such defects is to make use of the draw-in map as a basis for modifications to the binder system. Use of such a map can pin-point locations on the binder ring128where metal draw-in does not contribute to a defect free part. Comparison with actual draw-in at a trial part location indicates whether metal flow should be encouraged or restricted. After indicated changes have been made to the binder system a new trial part is made. This try-out approach is repeated to correct metal flow in the die set.The practice of the invention has been illustrated by illustrative, but not scope limiting examples.汉语翻译头衔在地图绘制冲压模具的试模美国专利7130708摘要金属板材成形是一种金属平板进入模腔形成产品的成型方法。吸收量是一个最重要的指标，控制所有冲压成形特点（应力），成形失败（劈叉、皱纹）和表面质量（扭曲）面板上的。一个新的模具冲压钣金零件重复一部分设计规范适应通过使用基于数学的冲压操作模拟特定的工程冲压条件下的特定部分的简化。冲压模拟是用来创建一个工程画地图的对比上选定位置加盖部分的外周边缘与原有的金属片的边缘对应的位置。生成的地图绘制在金属板的尺寸反映在所有模具的冲压件的冲压操作执行这样的位置对压边圈和凹模件压料面之间的金属片合适的位移。工程画尺寸模拟部分确定具体地点为适应集生产零件的模具压边圈胶表面系统的调整。发明家：王川道（特洛伊，MI，美国）果阿，诺曼（特洛伊，MI，美国）张，吉米J.（特洛伊，MI，美国）申请号：10 / 404728出版日期：10 / 31 / 2006申请日期：04 / 01 / 2003受让人：美国通用汽车公司（底特律，MI，美国）其他类：700 / 30，700 / 109，700 / 117国际班：g06f19 / 00；b21d37 / 20；g06g7 / 48搜索区：72 / 379.2，700 / 30，700 / 193，700 / 110，700 / 182，72 / 17.3，700 / 111，700 / 174，72 / 362，700 / 97，700 / 108，700 / 117，700 / 176，700 / 118，700 / 98，700 / 109，700 / 95美国专利文献：六百七十六万九千二百八十在制作传感器和实时绘制方法2004-08-03曹等人。72 / 17.3二百亿三千零一十六万七千零九十七对工具的设计方法2003-09-04医药保健品等。700 / 98二百亿二千零一十八万六千零七在制作传感器和实时绘制方法2002-12-12曹等人。五百九十七万四千八百四十七超塑成形工艺1999-11-02桑德斯等人。72 / 57主考官：皮卡德，狮子座副考官：kasenge，查尔斯律师，代理人或公司：hargitt，劳拉C.索赔：本发明：1。一种使钣金模具，重复做一个指定的成形从具有金属片边缘的金属片形成了部分的外周边缘部分形成方法；说模具包括模具型腔件金属片粘合剂表面和粘合剂的环压说空白对所述粘合剂表面上，粘结剂的表面和压边圈说包括珠槽表面绘制在控制板料在模具型腔中说表示空白的板料成形部分说，该方法包括：生产的成形计算机模拟说部分在预定的设计使用一个模拟所形成的部分的外周边缘相对于在板料边缘表示相应位置表示模具获得数据集模拟画在尺寸上位置的形成条件；在地图的绘制在尺寸模拟绘制；比较尺寸模拟画说在地图上表示审判钣金零件尺寸获得相应的画形成在所述金属板材成形模具用于适应说模具冲压的指定部分的重复说。2。一种方法是背诵在索赔1包括：成形板料成形模具说下预定工程形成条件试验的一部分；测量尺寸，绘制说边缘说试验的一部分在画的尺寸相应的位置表示图；比较得出维度说地图与审判钣金零件说在尺寸相应的画说；识别说边缘说试验的一部分，在尺寸的画不同于说的任何地点；改变说珠和/或槽面变化说画在钣金减少尺寸绘制差异说。3。一种方法是背诵在索赔2包括改变形状表示在相对应的位置珠和/或槽表面说的位置上说边缘说审判部分改变说画在金属片。4。方法如2包括重复索赔2步骤直到索赔说模具可以反复使表示指定的钣金零件。5。一种方法是背诵在索赔3索赔包括重复3步骤直到说模具可以反复使表示指定的钣金零件。6。一个尝试钣金成型方法模具适应重复使指定的成形从具有金属片边缘的金属片形成了部分的外周边缘部分；说模具，包括凸模模件，凹模腔构件与金属片粘合剂表面，和压胶环说空白对说料面，料面和压边圈说包括互补的珠环槽表面绘制在控制板料进入模腔时说空说成形运动说拳，说的方法包括：生产的成形计算机模拟说下预定的设计使用模拟说指定部分上形成的金属片边缘表示相应位置表示模具获得数据集模拟线性拉伸的尺寸在边缘位置的形成条件；做画地图表示模拟线性画尺寸；成形板料成形模具说下预定工程形成条件试验的一部分；测量出尺寸为边缘说试验的一部分在画的尺寸相应的位置表示图；比较得出维度说地图与审判钣金零件说在尺寸相应的画说；识别任何位置上的边缘说试验的一部分，尺寸画不同于说地图；改变说珠环和/或槽面变化说画在钣金减少尺寸绘制差异说。7。一种方法是背诵在索赔6包括改变表示在相对应的位置珠环和/或槽面说的位置上说边缘说试验的一部分。8。一种方法是背诵在索赔6其中形成运动说拳包括运动从一个角度说，第一接触金属片到最终形成点，表示空白已被推到与模腔的成员说的一致性，该方法包括：生产的成形计算机仿真部分时说说拳最后形成点说，形成说审判说最终形成点。9。一种方法是背诵在索赔6其中形成运动说拳包括运动从一个角度说，第一接触金属片到最终形成点，表示空白已被推到与模腔的成员说的一致性，该方法包括：生产的成形计算机仿真部分时说说拳是在中间形成点之间说第一接合点和最终形成点说，形成说审判部分说中间形成点。10。一种方法是背诵在索赔6包括重复说的形成、测量、比较、识别和改变模具可以重复步骤直到说将指定的钣金零件。11。一种方法是背诵在索赔7包括重复说的形成、测量、比较、识别和改变模具可以重复步骤直到说将指定的钣金零件。12。一种方法是背诵在索赔8包括重复说的形成、测量、比较、识别和改变模具可以重复步骤直到说将指定的钣金零件。描述技术领域本发明涉及钣金成形模具制作，方法和调试模具成形。更具体地，本发明涉及一种金属板材或地图绘制位移距离在一三或四分的数学指导试模在冲压的金属片部分外围模具，包括凸模，压边圈（S）和凹模的设计制作部分。本发明的背景传统的三部件模具冲压钣金件由打孔、装订环和凹模。这种模具是用来使制造多强、重量轻的物品。这些物品包括，例如，汽车车身板等结构件；飞机和电器板组件；和饮料罐。家庭形成的铁和铝金属合金已用于这些制造工艺。在一个典型的金属板材成形操作，平空白的金属保持在其周边在型腔表面的凹模和单拉入腔，对形面采用凸模成形面互补的凹模。该片是绘制和拉伸之间的工具和假设一个理想的形状。在制造的冲压件，如汽车车身板，经常是深口袋和小半径弯曲的面板，可以使用两组或两组以上的冲压模具的各阶段形成的一个合适的液压操作。在冲压作业的空白卡在一个空白的边凹模腔边缘表面周边称为粘合剂的环。压边圈之间的相互作用，插入的表和在凹模的边缘部分是使粘结剂形成无皱纹或眼泪的一部分关键。压边圈有珠按相邻的金属片成一个互补的凹陷槽，在凹模粘结剂部分创建适当的制约力量，防止金属片被吸引到模腔太自由了（和产生皱纹的金属片）或太严格（造成面板分割）。因此，对坯料的周圈卷曲的胶环系统掌握。当操作冲床的冲头与空白带来的接触，金属片画和/或延伸至成型腔。粘合剂珠/槽的相互作用在每个点周围的空白地方的金属片进入成形模具的整个外围。画在太小的金属粘结剂环系统可以导致在冲压件的眼泪或裂缝，和太多的拉制金属会导致皱纹和表面的扭曲。在量的画是由模具设计与施工，控制成形工艺参数（压边力、润滑、模具装置），和板材性能。在传统的模具开发和制造过程中，模具是根据以往的经验设计和模具是通过一系列的物理试验验证。这些试验是耗时和昂贵的，不能保证模具发展的成功。一个典型的汽车覆盖件，说一个挡泥板，单独的试用可能持续十二个月，耗资超过一百万美元。在以数学为基础的模具开发实践的今天，一个模具的设计进行评估和重塑通过电子试用通过先进的冲压仿真技术，包括冲压CAE（计算机辅助工程）项目，钣金成形仿真软件（例如，PAMSTAMP和DYNA3D）和高性能计算机。后车身面板的模具为例，设计或在数字世界中成功开发的模具构造，并试图在一个加工车间。然而，有一个模具和生产操作的日常使用工程之间的差异。和有差异的结果之间的数字仿真和物理模操作冲压厂生产的零件。问题的一个方面是，模具制造商不与数学基础如此熟悉模具工程原则，他们可以利用好数学基础的工作在调整模具冲压作业实际每天和普通金属板材料。因此，对于每一套模具加工试用期身体还可以采取几个星期或几个月，因为一直没有强大的程序可以检测并纠正制造人们之间的差异和实际模具的数学仿真，从它被建造的。本发明的目的是为符合实际冲压经验，使用特定的模具与模具先进的基于数学模拟和冲压操作提供一个过程。这是一个更具体的对象本发明使用的确切数额的金属片划在压边圈在选定的位置周围的空白边缘符合设定的模拟性能的虚拟模具的物理模操作的实用性和有效性提供依据的过程。本发明的概要本发明利用电流的数学基础能力，计算机执行的金属板材成形技术生产的数据集，可用于冲压模具调试人员迅速生产出无缺陷的冲压件采用冲压模具。本发明是一个过程，在此基础上，引入模腔的金属片的数量是一个关键的制造业指数，适当地反映实际应变的前提下，应力和变薄的金属冲压经验。它被认为是吸引量可用于预测冲压失败和控制绘制量在选定的位置，在空白的外围是模具制造商在车间调整设置以最大效率和最小的努力和成本做出好的冲压件模具的简单而强大的方式。根据本发明的实践中，数学为基础的过程是用来模拟冲压部分采用冲压模设置在由计算机根据指定的模具设计过程。数学基础的过程是用来预测量的金属片画在钣金生产无缺陷部分的冲床冲压行程在应变和应力水平。数学仿真考虑指定工程试模条件。这些条件包括空白，其力学性能如屈服强度的材料规格，抗拉强度和摩擦系数。工程试模条件还包括厚度和形状（几何）的空白，粘结剂的出行量，压边力（吨位），成形吨位，男性珠女珠（槽）结构、润滑等。一个精心设计的绘制地图的制备与萎缩的边缘部分在计算机模拟形成的原始毛坯的边缘。在地图的绘制显示的线性尺寸，例如，毫米，从平坦的空白形成的面板位置在绘制零件图的表。此外，像画在地图可以在中间部分形成阶段的基础，准备如对冲头的表观从与空白的初始接触到模具完成成形行程。试模的工人可以在地图使用工程画为基础，纠正实际画在空白的房模。在金属板上画在距离试验的一部分，是大于或小于地图尺寸合适的薪酬进行调整以珠的形状来增加或减少板料的流动。总是，在成形零件的边缘值的实际画纳入符合模拟冲压出的价值，是生产好的零件。本发明的优点是模具的试模人员可以专注于画在金属板的部分形成的一个事件，他们经常观察各冲压制造。现在，随着工程绘制地图的使用，模具调试人员可以更有效地整合实际板材尺寸与图画仿真得出的数学方法，在必要的试模过程中，调整珠在特定的位置，在地图的绘制出。本发明的其它用途和优点将详细描述在地图中绘制一个优选实施例中变得明显。附图简要说明图1是一种观点的形成车辆翼子板一三块模具成型表面。这个数字包括从上到下，与凹模外表面形成的金属片，压边圈的表面，与冲压成型表面。图2是一个扩大剖视图一个破碎的部分图1显示男性珠压边圈和插入的空白和潜在的冲头表面的凹模的外周表面的珠槽。图3是一个形成防护板的预制坯计划的看法。图4是一个成型的挡泥板
- 温馨提示:
1: 本站所有资源如无特殊说明，都需要本地电脑安装OFFICE2007和PDF阅读器。图纸软件为CAD,CAXA,PROE,UG,SolidWorks等.压缩文件请下载最新的WinRAR软件解压。
2: 本站的文档不包含任何第三方提供的附件图纸等，如果需要附件，请联系上传者。文件的所有权益归上传用户所有。
3.本站RAR压缩包中若带图纸，网页内容里面会有图纸预览，若没有图纸预览就没有图纸。
4. 未经权益所有人同意不得将文件中的内容挪作商业或盈利用途。
5. 人人文库网仅提供信息存储空间，仅对用户上传内容的表现方式做保护处理，对用户上传分享的文档内容本身不做任何修改或编辑，并不能对任何下载内容负责。
6. 下载文件中如有侵权或不适当内容，请与我们联系，我们立即纠正。
7. 本站不保证下载资源的准确性、安全性和完整性, 同时也不承担用户因使用这些下载资源对自己和他人造成任何形式的伤害或损失。
人人文库网所有资源均是用户自行上传分享，仅供网友学习交流，未经上传用户书面授权，请勿作他用。
川公网安备: 51019002004831号