《汽车模具工程项目案例》-2.汽车模具覆盖件技术设计过程中的重难点及注意事项-英语

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KeyDifficultiesandPointstoNoteintheTechnologyDesignProcessofAutomobileMoldCoveringParts

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I.CourseIntroduction

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KeyDifficultiesandPointstoNoteintheTechnologyDesignProcessofAutomobileMoldCoveringParts

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Intheprecisionmanufacturingsystemoftheautomotiveindustry,thetechnologydesignofautomobilemoldcoveringpartsisconsideredthecoresegment,anditsimportanceisself-evident.Itislikethe"externalsoul"ofautomobiles,notonlydeterminingtheappearancestylingthatautomobilesultimatelypresenttothepublicbutalsohavingaprofoundimpactontheoverallperformanceofautomobiles.

Imagineasleek-lined,uniquelystyledautomobileshuttlingthroughthestreetsofthecity,instantlyattractingtheeyesofthecrowd.Andallofthisstemsfromtheexquisitedesignofautomobilemoldcoveringparts.Butthisdesignprocessisbynomeansasmoothpath,likeclimbingamountainpeak,fullofchallengesandunknowns.Frommeetingincreasinglystringentaestheticstandardstoadaptingtocomplexandever-changingproductiontechniques;frombalancingthedelicaterelationshipbetweenmaterialperformanceandcosttomeetingthedifferentiatedrequirementsofdifferentvehiclemodels,eachsteprequiresprecisegraspbythedesigners.Next,let'sdelveintothekeydifficultiesandpointstonoteinthetechnologydesignprocessofautomobilemoldcoveringparts,illuminatingthewayforwardforexplorersinthefieldofautomobiledesign.

II.ExplanationofCoreKnowledgePoints

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Designprinciplesandoverallplanning:

Determinationofstampingdirection:Itdetermineswhethersatisfactorycoveringpartproductscanbedrawnanddirectlyaffectstheamountofprocesssupplementaryparts,theshapeoftheblankholdersurface,andthehardnessandservicelifeofthemold.

Determinationofblankholdersurfaceshape:Toachievethispurpose,theblankholdersurfaceshouldbeformedwithacertaininclinationangletoreducethedrawingdepthwhileformingaflatblankholdersurfacetoachievethebestpressingeffect.Theblankholdersurfacemustnothavelocalbulges,dents,orsags.

Determinationofprocesssupplementarysurface:Theprocesssupplementarysurfaceisnotonlyaconditionforrealizingdrawingbutalsoanecessarysupplementforincreasingthedegreeofdeformationandimprovingthecomponentstiffness.Itwilldirectlyaffectthedrawingformingaswellasthesubsequenttrimming,shaping,hemming,andotherprocesses.

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Thefollowingaresomeaspectsthatrequirespecialattentioninthedesignprocess:

I.Designprinciplesandoverallplanning

Determinationofstampingdirection:Itdetermineswhethersatisfactorycoveringpartproductscanbedrawnanddirectlyaffectstheamountofprocesssupplementaryparts,theshapeoftheblankholdersurface,andthehardnessandservicelifeofthemold.

Determinationofblankholdersurfaceshape:Theblankholdersurfaceshapeistheprimaryconditionforensuringthatthematerialdoesnotruptureandformssmoothlyduringthedrawingprocess.Toachievethispurpose,theblankholdersurfaceshouldbeformedwithacertaininclinationangletoreducethedrawingdepthwhileformingaflatblankholdersurfacetoachievethebestpressingeffect.Theblankholdersurfacemustnothavelocalbulges,dents,orsags.

Determinationofprocesssupplementarysurface:Theprocesssupplementarysurfaceisnotonlyaconditionforrealizingdrawingbutalsoanecessarysupplementforincreasingthedegreeofdeformationandimprovingthecomponentstiffness.Itwilldirectlyaffectthedrawingformingaswellasthesubsequenttrimming,shaping,hemming,andotherprocesses.

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Specificpointsofattentioninmolddesign:

Designofcornersandstraightlinesofdrawingparts:Setdrawingribsonstraightlinepartstobalancethefeedingspeed.

Designofinnerandouterringsofthemold:Drawingribsshouldbesetonboththecornersandstraightlinepartsofshallowdrawingparts,butonlyonedrawingribcanbesetonthecornerparts,while1~3drawingribscanbesetonthestraightlineparts.

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II.Specificpointsofattentioninmolddesign

Designofcornersandstraightlinesofdrawingparts:Setdrawingribsonstraightlinepartstobalancethefeedingspeed.

Designofinnerandouterringsofthemold:Drawingribsshouldbesetonboththecornersandstraightlinepartsofshallowdrawingparts,butonlyonedrawingribcanbesetonthecornerparts,while1~3drawingribscanbesetonthestraightlineparts.Iftherearemultipledrawingribs,theyshouldbe"looseontheoutsideandtightontheinside,"thatis,thedrawingribsontheouterringofthemoldshouldbe"looser,"whilethedrawingribsontheinnerringofthemoldshouldbe"tighter."

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Verificationandtestingofmolds:

Moldconformityverification:Verifywhetherthemoldinstallationdimensions,moldhardness,positionsofdowelpinsandpositioningblocks,cavitydimensions,etc.meettheregulationrequirementsofthedesigndrawings,andverifywhetherthemoldmeetstheassemblyadjustmentprocessconditionrequirementsstipulatedinthedesigndrawingsafterassembly.

Moldapplicabilityverification:Performdynamicverificationofregulationprocessparametersandregulationmassproductioncapabilitiesaccordingtoregulationproducts.

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III.Verificationandtestingofmolds

Moldconformityverification:Verifywhetherthemoldinstallationdimensions,moldhardness,positionsofdowelpinsandpositioningblocks,cavitydimensions,etc.meettheregulationrequirementsofthedesigndrawings,andverifywhetherthemoldmeetstheassemblyadjustmentprocessconditionrequirementsstipulatedinthedesigndrawingsafterassembly.

Moldapplicabilityverification:Afterthemoldmeetstheconformityverification,installtheassembledmoldontheregulationequipmentandperformdynamicverificationofregulationprocessparametersandregulationmassproductioncapabilitiesaccordingtoregulationproducts.

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Designfocus:

Coveringpartshapeanddimensionalaccuracy:Coveringpartsusuallyhavelargecontourdimensionsandcomplex3Dsurfaceshapes,requiringensuringdesignaccuracytomeetsubsequentprocessingandassemblyrequirements.

AdoptingadvancedCAD/CAMtechnologies:Using3Dmodelingsoftwareforthedesignofcoveringpartscanaccuratelycontroltheirshapeanddimensions.ThroughCAMtechnologyformoldmanufacturing,themanufacturingaccuracyandsurfacequalityofthemoldcanbeensured.

Materialselectionanddeformationcontrol:Itisnecessarytoconsidertheplasticity,strength,toughness,andothercharacteristicsofthematerial,aswellasitsdeformationbehaviorduringthedrawingprocess.

Optimizingmaterialselectionandtreatment:Selectsuitablematerialsaccordingtotheshape,dimensions,andservicerequirementsofthecoveringparts.Performappropriatepre-treatmentonthematerials,suchasannealingandquenching,toimprovetheirformingperformanceandfinalquality.

Drawingprocessdesign:Itisakeyprocessintheformingprocessofcoveringparts,requiringreasonabledesignofdrawingmoldsandprocessparameters.

Drawingprocessdesign:Itisakeyprocessintheformingprocessofcoveringparts,requiringreasonabledesignofdrawingmoldsandprocessparameters.

Precisecontrolofdrawingprocessparameters:Basedonsimulationresults,optimizethedesignparametersandprocessparametersofthedrawingmoldtoreducetheoccurrenceofdefectssuchastearingandwrinkling.

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Thefocusandsolutionsinthetechnologydesignprocessofautomobilemoldcoveringpartsmainlyinvolvethefollowingaspects:

I.Designfocus

Coveringpartshapeanddimensionalaccuracy:Coveringpartsusuallyhavelargecontourdimensionsandcomplex3Dsurfaceshapes,requiringensuringdesignaccuracytomeetsubsequentprocessingandassemblyrequirements.Highaccuracyrequirementstoensuretheassemblyaccuracyandappearancequalityofcoveringpartsonthewholevehicle.

AdoptingadvancedCAD/CAMtechnologies:Using3Dmodelingsoftwareforthedesignofcoveringpartscanaccuratelycontroltheirshapeanddimensions.ThroughCAMtechnologyformoldmanufacturing,themanufacturingaccuracyandsurfacequalityofthemoldcanbeensured.

Materialselectionanddeformationcontrol:Thematerialselectionofcoveringpartsiscriticaltotheirformingperformanceandfinalquality.Itisnecessarytoconsidertheplasticity,strength,toughness,andothercharacteristicsofthematerial,aswellasitsdeformationbehaviorduringthedrawingprocess.

Optimizingmaterialselectionandtreatment:Selectsuitablematerialsaccordingtotheshape,dimensions,andservicerequirementsofthecoveringparts.Performappropriatepre-treatmentonthematerials,suchasannealingandquenching,toimprovetheirformingperformanceandfinalquality.

Drawingprocessdesign:Itisakeyprocessintheformingprocessofcoveringparts,requiringreasonabledesignofdrawingmoldsandprocessparameters.Defectssuchastearingandwrinklingthatmayoccurduringthedrawingprocessneedtobeeffectivelycontrolled.

Precisecontrolofdrawingprocessparameters:Throughsimulationtechnology,predictthematerialflowanddeformationconditionsduringthedrawingprocess.Basedonsimulationresults,optimizethedesignparametersandprocessparametersofthedrawingmoldtoreducetheoccurrenceofdefectssuchastearingandwrinkling.

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Thedifficultiesandsolutionsinthetechnologydesignprocessofautomobilemoldcoveringpartsmainlycoverthefollowingaspects:

Predictionofmoldstrengthwearlife:

Atpresent,domesticmolddesignlackssystematicresearchinthepredictionofstrengthwearlife,resultingintheinabilitytoaccuratelycontroltheservicelifeofmolds.

Strengtheningresearchonmoldstrengthwearlifeprediction:Throughcomprehensiveaspectssuchasmaterial,lubrication,contactforce,relativeslidingspeed,formgap,andheat-treatedlayerorganization,researchthequantitativeanalysisofmoldsurfacewear.

Springbackcontrol:Springbackisacommonissueintheformingprocessofcoveringparts,especiallywhenusingadvancedmaterialssuchashigh-strengthsteelplatesandaluminum-magnesiumalloyplates,springbackcontrolbecomesmoredifficult.

Optimizingspringbackcontrolstrategies:Processcontrolmethodsincludechangingthesheetshape,binderforce,moldradius,frictionconditions,andotherformingprocessboundaryconditions.

Materialdeformationandwrinkling:Duringtheformingprocessofcoveringparts,duetothelargedifferencebetweenthethicknessandin-planedimensionsofthematerial,instabilitywrinklingandmaterialaccumulationwrinklingcaneasilyoccur.

Improvingmaterialdeformationandwrinklingissues:Intermsofstampingconditions,increasebinderforce,balancebinderforce,controllubrication,andmaintaingoodparallelismofthepressandmold.

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Thedifficultiesandsolutionsinthetechnologydesignprocessofautomobilemoldcoveringpartsmainlycoverthefollowingaspects:

Predictionofmoldstrengthwearlife:Thestrengthandwearlifeofmoldsarekeyparametersindesign,butpredictingtheseparametersisachallenge.Atpresent,domesticmolddesignlackssystematicresearchinthepredictionofstrengthwearlife,resultingintheinabilitytoaccuratelycontroltheservicelifeofmolds.

Strengtheningresearchonmoldstrengthwearlifeprediction:Throughcomprehensiveaspectssuchasmaterial,lubrication,contactforce,relativeslidingspeed,formgap,andheat-treatedlayerorganization,researchthequantitativeanalysisofmoldsurfacewear.Establishevaluationindicatorsformoldwearfailureandproposemethodsforpredictingandcontrollingmoldlife.

Springbackcontrol:Springbackisacommonissueintheformingprocessofcoveringparts,especiallywhenusingadvancedmaterialssuchashigh-strengthsteelplatesandaluminum-magnesiumalloyplates,springbackcontrolbecomesmoredifficult.Theexistenceofspringbackdirectlyaffectstheformingaccuracyofstampedpartsandincreasestheworkloadoftrialmolding,moldmodification,andshapecorrection.

Optimizingspringbackcontrolstrategies:Adoptprocesscontrolmethodsandgeometriccompensationmethodstoreducespringback.Processcontrolmethodsincludechangingthesheetshape,binderforce,moldradius,frictionconditions,andotherformingprocessboundaryconditions.Thegeometriccompensationmethodistomeasureorpredicttheamountofspringbackundercertainprocessconditionsandmodifythemoldshapeaccordingly.

Materialdeformationandwrinkling:Duringtheformingprocessofcoveringparts,duetothelargedifferencebetweenthethicknessandin-planedimensionsofthematerial,instabilitywrinklingandmaterialaccumulati