CAJ | 학술논문

激光拼焊板制车门内板不仅可以优化零件结构，还可以有效降低车门内板重量，但激光拼焊板制车门在成形中容易出现破裂和焊缝移动的现象。针对激光拼焊板制车门成形中容易出现质量问题，为提高零件工艺设计的效率，利用 Dynaform 软件对其建立了冲压成形的有限元仿真模型，在数值仿真过程中，对焊缝处采用共节点的简化建模方式，通过对冲压边界条件的调整，确定了压边力为1050 kN、拉深筋高度为6.5 mm和摩擦系数为0.05的充分润滑状态，仿真和试验结果表明：车门内板冲压成形后的焊缝处的厚度的计算结果与试验数据具有良好的一致性，并预测焊缝向薄板方向的最大移动量为6.61 mm。和实测值7.31 mm的误差为0.7 mm，能较准确预测焊缝的移动量，验证了仿真模型的准确性。该研究方法可为激光拼焊板制车身覆盖件的工艺设计及模具设计提供指导和依据。
격광병한판제차문내판불부가이우화령건결구，환가이유효강저차문내판중량，단격광병한판제차문재성형중용역출현파렬화한봉이동적현상。침대격광병한판제차문성형중용역출현질량문제，위제고령건공예설계적효솔，이용 Dynaform 연건대기건립료충압성형적유한원방진모형，재수치방진과정중，대한봉처채용공절점적간화건모방식，통과대충압변계조건적조정，학정료압변력위1050 kN、랍심근고도위6.5 mm화마찰계수위0.05적충분윤활상태，방진화시험결과표명：차문내판충압성형후적한봉처적후도적계산결과여시험수거구유량호적일치성，병예측한봉향박판방향적최대이동량위6.61 mm。화실측치7.31 mm적오차위0.7 mm，능교준학예측한봉적이동량，험증료방진모형적준학성。해연구방법가위격광병한판제차신복개건적공예설계급모구설계제공지도화의거。
Tailor welded blanks (TWBs) based on modern technology are widely applied in the production of auto body components, which can reduce the weight of auto body effectively, but the overall formability of the TWBs is different from single blank, the fracture and welded seam movement usually appear in the forming process. To find out the formability of TWBs, the test and numerical simulation should be carried out, which has been a main problem of weld modeling for TWBs in simulation. <br> The application od auto door inner panel made of TWBs can not only optimize the structure of the workpiece, but also effectively reduce the weight of the inner door panel. The fracture and welded seam movement usually appear in the forming process of Auto door inner panel made of TWBs. In order to avoid the quality problems, and at the same time to improve the efficiency of process planning, a simulation model on forming was developed using software Dynaform. <br> In this paper, a new simulation method for weld-line is worked out. Generally the weld modeling uses a rigid way in the weld-line, but for large component such as automobile panel, it makes lower efficiency and even can’t finish the calculation. Experience shows that, the fracture will not appear on the weld-line in forming process as long as the weld is qualified. And, in the phase of the component design, what we are concerning more about is the overall formability of the component, therefore a new simulation method for weld-line was brought out: to simplify the handling of the common nodes, which are taken as the common nodes of both sides of weld material. Using this calculation method, grid can be encrypted automatically in the simulation, so that the initial blank does not need to partitioned very small, and the calculation efficiency and stability can be improved. <br> Through adjusting the simulation parameters, the appropriate blank holder force, draw bead and lubrication state were determined. The optimization and selected conditions for the forming simulation are that the blank holder force is 1 050 kN, the height of draw bead is 6.5 mm and the friction coefficient is 0.05 for the effective lubrication. The experimental result was well coincident with the numerical simulation results at thickness, the predicting movement value of weld-line is 6.61 mm, and the test value is 7.31 mm, the error is 0.7 mm, this verified the validity of numerical simulation. The amount of welded seam movement can be predicted accurately with the method, so the forming quality can be estimated. The method can shorten the time to adjust parameter in stamping repeatedly, and improve the efficiency from design to production for new automobile body cover made of TWBs. The analysis method based on numerical simulation technology is helpful for process planning of automobile body cover made of TWBs, and can provide a reference for its mould design.