货车下侧门论文：货车下侧门数值分析Dynaform模具设计

1、【中文摘要】铁路货车敞车下侧门是典型的中厚板冲压件，成形过程中容易产生拉裂、变薄、划痕、起皱、回弹等质量问题。生产中对这类零件的工艺设计仍然采用类比方法，依靠定性分析、物理模拟加实验验证，理论分析严重滞后。从生产中积累的经验知识存在不直观、不系统的缺陷，而成形数值模拟研究可得到直观的动态成形效果显示,其计算结果可指导实际生产，降低废品率，提高模具使用寿命，因此对这类零件进行系统的数值模拟研究具有理论和实践上的双重价值。本文采用Dynaform软件数值模拟预测了下侧门起伏成形中可能出现的问题或缺陷，优化整个成形工艺过程，修改和优化了模具设计参数,为下侧门成形工艺和模具设计提供了理论依据，并为试模

2、提出了具体方案。（1）采用Dynaform板料成形有限元模拟软件对铁路货车敞车下侧门成形的两种成形方案进行计算机数值模拟，并对数值模拟结果进行比较分析，最终确定了在2500T的水压机起伏成形和2000T冲床切边两道工序的冲压工艺方案。（2）通过Dynaform数值模拟,研究了材料性能、毛坯形状、模具间隙、压边力等对下侧门成形质量的影响，得出了下侧门起伏成形的最佳冲压工艺为：材料采用本钢09CuPCrNi-A、毛坯形状为1425X1120的矩形毛坯、模具间隙采用坯料厚度的1.0倍、压边力为120T。数值模拟为模具设计提供了可靠参数,从而缩短模具开发周期、降低模具开发成本。（3）以数值模拟结果为指

3、导，进行了下侧门起伏成形的模具设计和冲压加工。实验表明,Dynaform较好地模拟了下侧门起伏成形过程，模拟结果与实际基本相符,数值模拟节约了调模时间和实验费用。最终使模具调试时间缩短50%以上，产品厚度差在5%以内，其它形状及尺寸达到产品图要求。【英文摘要】Down-sidedoorofwagonisatypicalmiddle-thickplatestampingproduct,whichexistsqualityproblemsofcracking,thinning,scratches,wrinkleintheprocessofforming.Nowadaystheproductionp

4、rocessofdesignofthiskindofproductsstillusesanalogymethod,relyingonqualitativeanalysis,physicalsimulationandexperimentalvalidation,withtheoreticalanalysisseriouslylagging.Withthedrawbacksofunintuitiveandnone-systemicoftheproductionexperienee,andthenumericalsimulationresearchofformingcanshowthedynamic

5、calculationresults,guidetheactualproduction,reducescraprate,improvetheservicelifeofmould,thereforethenumericalsimulationsystemofthiskindofpartsisvaluablebothintheoryandinpractice.ThispaperadoptedDynaformsoftwaretopredicttheproblemsanddrawbacksinthedown-sidedoorformingprocess,optimizedthewholeforming

6、craftsprocess,modifiedandoptimizedthemodeldesignparameters,providedtheoreticalfundamentsofdown-sidedoorformingandmodeldesign,andproposedtheidiographicprojects.Firstly,thepaperadoptedDynaformsoftwaretoconductthenumericalsimulationofdown-sidedoorofwagonofthetwoformingplans,comparedthesimulationresults

7、,andfinallyestablishedthetwo-stepstampingprocessofundulateformingunderhydraulicpressof2500Tandpunchingof2000T.Secondly,thepaperstudiedthefactors,whichinfluencetheformingquality,suchasmaterialsproperties,blankshapeandmoldclearanceviaDynaform.Throughtheanalysisofnumericalsimulation,Anoptimalparameterc

8、ombinationwasobtainedthatthematerialshouldbe09CuPCrNi,therectangularshapeshouldbe1425x1120,theclearanceofthemouldsshouldbe1.0timesofblankthicknessandtheblank-holderforceshouldbe120T.Thenumericalsimulationprovidedreliableparametersinthemoulddesignsoastoshortenthedevelopmentperiodandreducethedevelopmentcost.Thirdly,thepaperresearchedthemoulddesignandstampingprocessofthedown-sidedoorundertheguidanceofnumericalsimulation.TheexperimentsshowthattheDynaformsoftwarecansimul