国内外轿车覆盖件模具设计概况--中英文翻译.doc

Domestic and foreign car coverage Die Design OverviewA.S. Pouzada, E.C. Ferreira and A.J. PontesAbstract : In introducing the current domestic car stamping die design and manufacture of the foundation, expounded foreign auto company cars panel particular panel of the stamping process and die design status application of new technologies .Key words : mechanical manufacturing; Car panel; Stamping technology; Mold Design 1 Introduction In recent years, Chinas car market has developed very rapidly in 2002 in car sales more than one million on the basis of in 2003 to 2 million people relations forward, reaching 1.97 million. However, in the car heat rapidly warming, had to face the embarrassment of this reality-market best-selling vehicle for the majority of people must be directly imported from abroad. As domestic car cover mold design and manufacturing capability on the whole is relatively weak, in order to produce these models, each company had to spend hundreds of millions or hundreds of billion of overseas procurement die. People with foreign automobile companies, because the relatively small scale of production, This has resulted in motorcycle smoothing wood into the mold much higher than foreign cars, This is also produced cars along with high wood manufacturing into one of the main reasons. 2 Domestic car coverage Die development capability Major car manufacturers to Die : Die Manufacturing Co. Ltd. of FAW, Dongfeng Motor Die Works, Tianjin Automobile Die Company, CAC Integration Technology Co., Ltd Nanjing mold equipment, Shanghai Auto Body 1000 margin Die Company. Most people as a domestic car production and sales of commercial-vehicle population of Shanghai Limited, also has its own mold design and manufacturing departments (TMM Division). Currently, Although domestic Die in Car cover the mold design and manufacturing has a small capacity, auto plants can undertake some development projects die, but for a very high surface accuracy and surface quality requirements of the outside panel. It is especially the high-grade cars outside panel, auto plants rarely die by the will of such domestic development.Shanghai Public Motors Limited in order to reduce vehicle production costs, but also to increase the companys core technical competencies, Since the beginning of 2001, set foot in the car stamping die design and manufacturing fields. 2001 -2002 completed POLO cars manually presses the production line 10 Die simple parts , the companys quality assurance department as well and put into production. Beginning in 2002, the type of people to the complex, automation, 6000kN the design and manufacture of automatic production line POLO cars tyres. Die Block (dimensions of the parts, deep drawing deep, complex shape) in 2003, in order to further enhance the design and manufacture of mold ability and level We get involved in the Multi-Position 20000kN Press and 10000kN automatic production line of die design. Shanghai over the past number of people in many public spaces 20000kN Press on the use of the mold, all u need to progress, Die domestic business still lacks the ability to design and manufacture the mold. To this end, we chose POLO Car column plate mold design. 20000kN Multi-Position Press is the worlds most advanced presses, integration, a very high degree of automation. Of course, this right mold design requirements also increased accordingly. Parts Feeding height, distance, location manipulator strict requirements ensure that the manipulator in the course of the campaign and die without interference, so the mold design for space on a small lot. In considering many factors, we finally completed the whole mold design, CAD state assembly as shown in figure 1. In addition, we have completed the POLO cars 10000kN automatic production line of the rear wheel cover mold design, In last years build on that. These successful completion of the Shanghai marks the number of people die design capability has reached advanced domestic level. thus for the future of Shanghai people die Domestic car lay a solid foundation. Nevertheless, with the international advanced level, the more people there are still gaps, For example, in the car outside cover mold design or from the air. Die in Car, the most difficult of the outer covering die design, mainly in the following two aspects :(1)Overcome by the resilience of parts surface deviations Breakdown, wrinkling, Rebound car is stamping process of forming the main shortcomings, as car outside panel dimensions. deep drawing shallow, plastic deformation low level generally will not crack, Resilience as a result of such parts on the manufacturing process and the main problems, it will seriously affect the parts with the mutual relations. Finite element simulation software in the stamping die design universal application, has been able to accurately predict rupture and wrinkle-free. thus contribute to the design of appropriate auxiliary surfaces to improve the process of drawing materials flow, improve parts forming ft. However, to date) unknown. Most of the finite element software can not be accurately forecast Stamping Die them removed from the rebound after deformation. Therefore, the external panel dealing with the resilience of the major changes to rely on the experience of the die face, stamping parts are forming over, to offset rebound led to the deformation. (2)Stamping the pick-up As foreign coverage (eg front cover plate, the roof and fender panels) are subject to complex flanging plastic or anticipated beading crafts, This makes the design of the mold structure, we must consider the ram after forming the pick-up, the current people are relying on more complex Wedge institutional linkages to achieve some of the work to mold parts his resignation to achieve to enable them to pieces. The resulting mold of the entire structure is very complicated.3 Foreign coverage Die Design Currently, foreigners Motors Corporation in order to reduce mold development and manufacturing costs, shorten production cycles, In addition to cars outside panel of people out of the car Stamping Die Mold were left to professional companies (such as Fontana Pietro.Kuka.Laepple.Schuler Cartec.Ogi-ha la-Fuji Techniaca etc.) to design and manufacture, these companies have strong development capabilities, and in some parts of the manufacturing mold with unique advantages. But as auto plants, taking into account the development of new models in the process of confidentiality, such as the right-wing boards, suitcase covers, doors, side-Wai, the roof front cover and other sensitive parts of the die, die by their own manufacturing sector to design and manufacture. 3.1 Software Environment Stamping die design, in addition to the need for CAD software, also large-scale application of the finite element simulation software If AutoForm.PamStamp. DynaForm. Indeed, aided design stamping process. Below, AutoForm as an example to show how the use of CAE software design process of drawing surfaces.AutoForm is supplied by the Swiss Development professional rapid simulation of sheet metal forming software can be used in sheet, welded plate stamping, such as Hydroforming process simulation, with different functional modules, can also be used for single-step stamping parts and the simulation of forming processes of drawing surfaces (Addendum) Design . Car stampings, About two-thirds of the use of AutoForm Diedesigner Module Module Design A ddendum the module under specified by the designer or by the software automatically generate pressure-ring face and and the process of multi-added section of the line (Profile), to produce rapid-added process, Drawing for the simulation process, as shown in Figure 2. V-ring face and Profile parameter can be the adjustment. This rapid design is based on surface Addendum Construction of the rough, curved surface film itself, and between the curved surface of the film is not very continuous fairing, Despite this surface is not used directly to the mold surface machining. But the simulation accuracy is not affected people. According to the simulation results. designers can easily add-on technology adjustment until simulation results meet design requirements. Finally, will Blankholder circle Profile Addendum to surface and neutral data format output IGS or VDA, CAD software for surface reconstruction and digital-analog integrated products, will be able to be machined can use the drawing process a few Die Mold.Stamping Process traditional design methods : First, on the basis of experience, the use of CAD technology to add noodles. Secondly, CAD will be transmitted to the model number of AutoForm software such as CAE deep drawing process simulation; According to the simulation results. in CAD add-on process adjustments and a few new CAD - CAE pass to start new simulation, Until meet the requirements for competition. This is one from CAD to CAE to return to the CAD kept in the process. Because each of the CAD surface structure than in AutoForm are complex, therefore, The whole process will have to spend much more time. And the new method of stamping process in the design stage, Diedesigner Module used in AutoForm software design and adjust the deep drawing process surfaces with the traditional design methods, we will be able to greatly improve the efficiency of design.A AutoForm is due to the rapid simulation software in a relatively short time stamping parts of the complicated process of forming the evaluation of membrane modules used to model discrete geometry, bound to reduce the simulation accuracy, therefore, Some car companies prior to the start of mold design will use high-precision simulation of the CAE software, Germany on the number of people using the software Indeed, Drawing on procedures for the simulation again (Indeed calculation software is based on the thickness of the shell element. to be more accurate results, However, the calculation of time spent AutoForm is usually several times that of the 10, The software is applicable to the ultimate test), Drawing all must pass Indeed Process simulation and validation to be feasible, in order for mold design.Mold design complete, the combination of drawings through the bubble acceptance model (Figure 3) different procedures with different colors of the lines marking the bubble model, the so intuitive and clear. Technology should also be organized, including designers, project planning, mold testing, Die operators and other stakeholders to discuss acceptance. For the stamping process difficult to solve the problem of forming, product development should also be invited to discuss personnel, look for changes in product design possibilities.3.2 Rebound amendment response The former is known, the rebound was cars outside panel forming process of the main questions are covered plate before example, conduct detailed analysis. Usually panel of the rebound following two categories :Large flat surface caused by the elastic response of buckling or collapse, as illustrated in figure 4, Part C Click below, dotted said parts removed from the mold and rebound occurred after the position. In such cases, the design process is not normally be considered. Technology products in a few die-face with some of the data from the product development departments of consistent data, and for die manufacturing. To tryout, and the specimens were seized compared with measurements, according to the deviation of drawing surface model amendment. If designers to control such problems have very rich experience, can be estimated in advance surface elastic recovery and the direction of offset, and will reverse its superposition of several product-development, Rebound consider seeking deformation of the surface of deep drawing process, the calculation process requires specialized computer software to accomplish, In Germany public, using the ICEM. Flanging plastic part by bending the rebound fold angle changes, as illustrated in figure 4 B Click below. For this kind of problem, in addition to the Department of Drawing and cutting edge, but also including flanging and Wedge plastic, plastic take-off process is forming 2 -3, to offset the springback. The process design work completed and reflected in the number of program modules. 33 Wedge new outer body mold coverage on the application Currently, many of the new models outside panel, fender panels (Figure 5) front cover plate, the roof flanging plastic processes, used as a revolving Wedge, new technology. The working principle see figure 6, rotating Wedge part of the cavity is required plastic stamping parts of the region, when the plastic process is complete, Cylinder - driven carriers to promote Wedge around rotating drum rotation, so as to achieve the purpose of the yield components, After the convenience of plastic parts, removed from the mold. Rotating Wedges advantages are : plastic parts for stamping parts and materials entrusted part of the mosaic is very fairing, Therefore, there is no obvious parts indentation; Die simple structure; maintenance is simple and low cost. 4 Concluding remarks In recent years, through the tireless efforts and the car stamping die design and manufacturing capabilities made significant progress. However, the car is especially luxury cars outside the coverage of mold development, the international level and there are still more people gap. However, this gap is not narrowing, So long as we strengthen international exchanges and learn from their foreign counterparts in designing and manufacturing experience, car will be able to accelerate the coverage Die domestic process. References1 C. Burke and R. Malloy, An experimental study of the ejection forces encountered during injection molding, SPE ANTEC Tech. Pap. 37 (1991). 2 R. Balsamo, D. Hayward and R. 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Sci. 45 (2005), p. 325. 16 Friction and Wear Testing Source Book, ASM International, Ohio, 1997. 17 ISO 8295, PlasticsFilm and SheetingDetermination of the Coefficients of Friction, 1995. 国内外轿车覆盖件模具设计概况A.S. Pouzada, E.C. Ferreira and A.J. Pontes摘要: 在介绍目前国内轿车冲压模具设计制造情况的基础上，阐述了国外汽车公司轿车覆盖件特别是外覆盖件的冲压工艺设计现状及模具新技术应用情况。关键词: 机械制造;轿车覆盖件;冲压工艺;模具设计1前言近几年来，我国轿车市场发展十分迅猛，2002年在轿车销售超过100万辆的基础上，2003年则向200万辆大关迈进，达到了197万辆。然而，在轿车热迅速升温的同时，不得不尴尬地面对这样的现实市场上热销的绝大多数车型是直接从国外引进的。由于国内轿车覆盖件模具设计制造能力从总体上看还比较薄弱，为了生产这些车型，各大汽车公司不得不耗资几亿、十几亿元采购海外模具。与国外大汽车公司相比，由于生产规模比较小，这就造成单车均摊的模具成本远高于国外车，这也是造成国产车整车制造成木居高不下的主要原因之一。2 国产轿车覆盖件模具开发能力国内主要的轿车模具制造商有:一汽模具制造有限公司、东风汽车模具厂、天津汽车模具有限公司、成飞集成科技股份有限公司、南京模具装备有限公司、上海千缘汽车车身模具有限公司等等。作为国内最大轿车生产销售商上海大众汽车有限公司，也有自己的模具设计制造部门(TMM部)。目前，虽然国内模具商在轿车内覆盖件模具设计制造方面已小有能力，并可承接整车厂的部分模具开发项目，但对于有很高型面精度和表面质量要求的外覆盖件，特别是中高档轿车的外覆盖件，整车厂很少会将这类模具交由国内开发。上海大众汽车有限公司为了降低整车生产成本，同时也为了提高公司的核心技术能力，从2001年开始，涉足轿车冲压模具设计制造领域。2001年-2002 年完成了POLO轿车在手动压机线上生产的10只简单零件的模具，通过了公司质保部门验收并投产。2002年开始向大型化、复杂化、自动化发展，设计制造了6000kN自动线上生产的POLO轿车备胎座模具(该零件外形尺寸大、拉深深度深、形状复杂)2003年，为进一步提高模具设计制造的能力和水平，我们涉足20000kN多工位压力机和10000kN自动线生产使用的模具设计。过去上海大众在20000kN多工位压力机上使用的模具，全部需进u,国内模具商还没有能力设计制造这样的模具。为此，我们选择了POLO轿车中柱内板的模具进行设计。20000kN多工位压力机是世界上最先进的压力机之一，集成化、自动化程度非常高，当然这对模具设计的要求也相应地提高。零件的送料高度、步距、机械手的位置有严格的要求，还要保证机械手在运动过程中与模具无干涉，这样给予模具设计的空间就小了很多。在考虑诸多因素之后，我们最终完成了整套模具的设计，其CAD装配状态如图1所示。另外，我们还完成了POLO轿车在10000kN自动线上生产的后轮罩的模具设计，在去年的基础上更进一步。这些工作的顺利完成，标志着上海大众模具设计能力已经达到了国内先进水平，从而为今后上海大众汽车模具国产化打下了坚实的基础。尽管如此，与国际先进水平比较，仍有较大差距，比如在轿车外覆盖件模具设计方面还是空自。 在轿车冲模中，难度最大的是外覆盖件模具设计，主要表现在以下两个方面:(1)克服由回弹造成的零件型面偏差破裂、起皱、回弹是轿车冲压件成形过程中的主要缺陷，由于轿车外覆盖件外形尺寸大、拉深深度浅、塑性变形程度低，一般不易拉裂，因而回弹就成为该类零件制造过程中的主要问题，它将严重影响零件间的相互配合关系。有限元模拟软件在冲压模具设计中得到普遍应用，已经能够比较准确地预测破裂和起皱，从而有助于设计合适的工艺补充面来改善拉深过程中材料的流动状况，提高零件的成形ft。然而，迄今为止，大多数有限元软件还不能精确地预测冲压件从模具当中取出后的回弹变形。因此，对外覆盖件回弹问题的处理，主要还是依靠经验来修改模具型面，使冲压件过正成形，来抵消由于回弹导致的变形。(2)冲压件的取件由于外覆盖件(如前盖外板、车顶、翼子板)都需进行复杂的翻边整形或预卷边工艺，这就使得在模具结构设计时，必须考虑冲压件成形后的取件问题，目前，大都依靠复杂的多斜楔机构联动来实现模具工作部分对零件让位，以实现方便取件，由此造成整个模具的结构十分复杂。3 国外覆盖件模具设计目前，国外大汽车公司为了降低模具开发、制造成本，缩短生产周期，将除轿车外覆盖件之外的大部分轿车冲压件的模具