Case study on quality control of multi - station progressive stamping

To improve the quality of multistep progressive stamping, reduce the cost of mould manufacturing of a car door rail structure involved in the process of punching, bending, deep drawing, trimming, plastic, flanging forming process and springback uninstall has carried on the finite element numerical simulation of the carrier of the possible distortion in predicting the forming, deep drawing and flanging bursts and springback of forming defects, such as The causes of defects are analyzed, and the corresponding solutions or control measures are put forward. The ideal simulation results are obtained by modeling again Based on the numerical simulation results, the multi-station progressive stamping test was carried out, and two parts of a door rail structure with qualified forming quality were successfully produced, which can meet the requirements of mass production.

The rapid development of automobile industry has put forward higher requirements on the production efficiency, quality and cost of automobile parts. The unique advantages of"high precision high efficiency and high life of multi-station progressive memes have been applied more and more widely in automobile parts processing. But multi-station progressive stamping forming quality affected by many factors, such as blank geometry, carrier form mold structure and process parameters, such as dependence on experience design of the mould often can make the parts in the process of forming defects such as wrinkling, cracking,and the spring back forming quality is difficult to control, need repeated test and repair the mold in the manufacturing process, product manufacturing cost is high the cycle is longThrough the effective use of numerical simulation the elastic-plastic deformation of sheet metal in the forming process can be calculated, the forming defects can be predicted accuratelyan optimized forming process or die structure can be obtained and the forming quality can be improved eventually.

Taking the stiffening plate of the front rail of an automobile as an example, the stamping process of the progressive die was simulated and the possible problems such as conveyor belt deformation and inaccurate blank development were predicted, and the material belt of the progressive stamping was optimized.The whole process of 13- station stamping forming of automobile mounting seat ofahigh strength steel plate was simulated by finite element method. The problem of easy cracking in forward and reverse drawing was solved by modifying the shape of blank and convex hull.The forming quality is improvedBut so far, there is no progressive stamping for multi-station.

Research report on defect prediction and quality control during forming processIn this paper, taking a car door rail structure as the research object, using Dynaform software to the multi-station progressive stamping forming process and springbackuninstall finite element modeling, through the numerical simulation to predict the forming process of the carrier of possible distortion deep drawing and flanging bursts and springback of forming defects such as according to reasons under effective control.

1. Finite element modeling and numerical simulation

The schematic diagram of the rail structure of a car door is shown in Figure 1:

The material is DX53D galvanized sheet with thickness of 1.2mmThe guide rail structure is used for the electric glass elevator of the automobile. The curved surface of the parts must be consistent with the radian of the door glass, and the groove, bayonet and other local characteristic shapes are compatible with other parts. These parts must ensure good forming quality and dimensional accuracy.Through the process analvsis of the structure of the gide rai. the fina stamping process scheme that adopts13-station, double-side carrier, double-blous sample and left and right parts stamping forming at the same time is determined. The layout design is shown in Figure 2:

1- Punching and guiding holes process notches;2-trimming punching process incision;3-trimming, punching processincision;4- bending -drawing;5-Punching positioning holes and trimming;6- trimming,punching;7-trimming,punching;8-plastic;9-shaping flanging;10-rivet hole;11-rivet hole;12-punching and trimming;13- Cut off the blanking