鋁合金板作為一種重要的輕量化材料，以其高比強(qiáng)度、良好的耐腐蝕性、良好的焊接性和高回收率等優(yōu)勢，成為僅次于鋼材的第二大汽車材料。然而,與傳統(tǒng)汽車相比鋼鐵、鋁合金板形成自己的性能有一定的缺點(diǎn),容易起皺和開裂的過程中形成和回彈缺陷,尤其是對發(fā)動機(jī)蓋板內(nèi)復(fù)雜,相對厚度小,表面質(zhì)量要求高,大封面元素的缺點(diǎn)變得更為突出。
　　As an important lightweight material, aluminum alloy plate has become the second largest automotive material after steel due to its advantages of high specific strength, good corrosion resistance, good weldability and high recovery rate. However, compared with the traditional automobile, steel and aluminum alloy plate have some shortcomings in forming their own performance, which is easy to form and rebound defects in the process of wrinkling and cracking, especially for the complex inside of the engine cover plate, small relative thickness, high surface quality requirements, the shortcomings of the large cover elements become more prominent.

　　為了進(jìn)一步推動鋁合金板在汽車工業(yè)中的應(yīng)用，如何克服鋁合金板材料的性能劣勢，獲得大程度滿足要求的成形件，已成為行業(yè)內(nèi)的熱點(diǎn)問題。
　　In order to further promote the application of aluminum alloy plate in the automobile industry, how to overcome the performance disadvantage of aluminum alloy plate materials and obtain the forming parts that meet the requirements to a large extent has become a hot issue in the industry.
　　其次，影響鋁合金板材沖壓成形的原因
　　Secondly, the reasons that affect the stamping of aluminum alloy sheet
　　一般來說，影響汽車零部件成形性能的主要因素是材料性能、成形工藝參數(shù)和模具設(shè)計。在覆蓋件沖壓成形中，工藝參數(shù)和模具的優(yōu)化是提高成形質(zhì)量的主要考慮因素。
　　Generally speaking, the main factors that affect the forming performance of auto parts are material performance, forming process parameters and die design. In the process of panel stamping, the optimization of process parameters and die is the main factor to improve the forming quality.
　　基于鋁合金的汽車發(fā)動機(jī)罩內(nèi)板成形工藝研究
　　Research on forming technology of automobile engine hood inner plate based on aluminum alloy
　　通過拉伸試驗(yàn)，獲得了6016鋁合金板的力學(xué)性能參數(shù)，建立了高精度的有限元分析模型。通過拉延變形模擬，探討了材料N值、坯料厚徑比T /D、壓邊力、摩擦系數(shù)和凹模圓角半徑對板料拉延性能的影響。太陽Z C等人CAD軟件和有限元相結(jié)合,并使用一個可行域序列二次規(guī)劃算法來優(yōu)化初始過程輔助表面,并改變了幾何參數(shù)使工件的厚度變化和表面質(zhì)量達(dá)到好的,這是成功地應(yīng)用于方形盒子和減震器。
　　Through tensile test, the mechanical properties of 6016 aluminum alloy plate are obtained, and a high-precision finite element analysis model is established. Through the simulation of drawing deformation, the influence of material n value, blank thickness diameter ratio T / D, blank holder force, friction coefficient and die fillet radius on the drawing performance of sheet metal is discussed. Sun ZC and other CAD software are combined with the finite element method, and a feasible region sequential quadratic programming algorithm is used to optimize the auxiliary surface of the initial process, and the geometric parameters are changed to make the thickness change and surface quality of the workpiece reach the best, which is successfully applied to the square box and the shock absorber.
　　(1)模具對板料成形性能有重要影響。通過對可能出現(xiàn)的成形缺陷進(jìn)行數(shù)值分析，并對模具表面進(jìn)行持續(xù)優(yōu)化，達(dá)到改善物料流動的目的，從而減少局部結(jié)構(gòu)引起的成形缺陷，提高成形質(zhì)量。
　　(1) Die has an important influence on sheet metal formability. Through the numerical analysis of the possible forming defects and the continuous optimization of the die surface, the purpose of improving the material flow is achieved, so as to reduce the forming defects caused by the local structure and improve the forming quality.
　　(2)工藝參數(shù)對成形質(zhì)量有顯著影響。壓邊力小，模具間隙大，有利于緩解鈑金減薄，保證零件精度和強(qiáng)度;在一定范圍內(nèi)，隨著壓邊力的提升，零件的大正回彈量略有減小，大負(fù)回彈量隨著壓邊力的提升而提升，整體回彈量隨著模具間隙的提升而提升。
　　(2) The process parameters have significant influence on the forming quality. In a certain range, with the increase of the blank holder force, the maximum positive springback of the part decreases slightly, the maximum negative springback increases with the increase of the blank holder force, and the overall springback increases with the increase of the die gap.
　　(3)通過調(diào)整型材補(bǔ)償和工藝參數(shù)，可進(jìn)一步降低零件回彈。研究鋁合金板料成形質(zhì)量的影響規(guī)律及模具表面優(yōu)化可以作為實(shí)際生產(chǎn)的理論依據(jù)和重要參考。通過模具制造和調(diào)試，試驗(yàn)結(jié)果驗(yàn)證了發(fā)動機(jī)罩內(nèi)板的沖壓成形，與仿真優(yōu)化結(jié)果吻合較好。
　　(3) The springback of parts can be further reduced by adjusting profile compensation and process parameters. It can be used as the theoretical basis and important reference for the actual production to study the influence law of the forming quality of aluminum alloy sheet and the die surface optimization. Through die manufacturing and debugging, the test results verify the stamping forming of the engine hood inner plate, which is in good agreement with the simulation optimization results.
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