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1、冲压成型标准及流程 stamp formability standard and process,成型分析流程简介 formability analysis flow introduction,VVA：虚拟装配 L1：初版数据发放 MMR：制造数据发放 P2：终版数据发放 TP：调试 ATDS:调试分析表,MMR Buyoff Report,L1-4 AEBO Report,P2 Formability Package,Final ATDS,成型分析软件及参数设置 Formability Analysis Software And Setup Parameters,一、分析软件的使用：Form
2、ability Analysis Software1.模具设计前优先使用顺序：AutoformPamstampDynaformUntil buyoff to start die design preferential order2.模具设计时优先使用顺序：PamstampDynaformAutoformAfter buyoff to start die design preferential order3.输出文件: Output DocumentSimulation ReportFormability ReportAdvanced Engineer ReportTryout Report 二
3、、参数设置：Setup Software Parameters 1.材料参数设置根据仿真分析输出报告，规格符合通用标准。Material setup parameters follow to simulation report , specification conform to GM standard. 2.软件参数：摩擦系数、压边力、拉延筋Setup Parameters: friction coefficientsbinder forcedrawbead,成型分析报告模板 Model of Formability Analysis Report,成型分析关键控制要素：Key to Suc
4、cess in Using Formability1.材料力学性能及仿真模拟计算分析。material mechanics and computing analysis technology 2.塑性力学原理、接触摩擦运算、成型压力、板料流入量。Plasticity Theory, Contact Algorithm, Friction Law, Forces, and Draw-in Amounts (Metal Flow) 3.假定模具工作时无变形、表面光洁、合模到底、料厚间隙准确、真实圆角、理论摩擦条件、压力分布均匀。Assume the tools are rigid bodies,
5、mirror finishing, perfect spotting, exact one metal thickness offset clearance, true radius, and theoretical tangency, press balanced. 4.板料机械性能与设置吻合，化学成分和表面粗糙度符合标准。The mechanical properties of blanks are close to typical case. The chemical compositionand surface roughness meet the specifications. 5.
6、 工艺设置符合GM标准Follow GM Standards (Processing, Layout, Die Design, Press, and Automation) 6.利用成型分析报告指导调试。Use Formability Package to guide tryout 7.利用平衡块0.1mm间隙使筋控制板料流入。Use 0.1 mm equalizing blocks to let beads control metal flow from binder,成型分析相关标准 Formability Analysis Relate Standard,板料：Blank板料要求：Bla
7、nk Requirement 分析调试所使用的板料必须与产品设计材料一致。 All material used for tryout will be from the designated production. 板料尺寸：Bank size 最大外形尺寸 Maximum shape size buy point 压边圈闭合板料尺寸 Blank size of position at binder closure 板料流入量 Draw in map 成型分析时的尺寸用于指导模具调试，调试完成后的板料实际尺寸用于修正模拟尺寸。 Simulation blank size can be used
8、for guiding die tryout work , actual tryout blank size could correct the simulation blank size .,成型分析相关标准 Formability Analysis Relate Standard,压料筋标准：Bead Standard 压料筋类型：方筋、圆筋、台阶 Bead style : rectangle beadround beadstep bead,Forming Limit Diagram ( FLD)成型极限图,该图是发生在板料成形时的经验曲线，显示双轴应变水平超过此范围可能发生的缺陷 An
9、empirical curve showing the biaxial strain levels beyond which failure may occur in sheet metal forming.,该图显示的应变为分析网格变形的测量数据显示范围。 The strains are given in terms of major and minor strains measured from deformed circle, previously printed on to the un-deformed sheet.,Forming Limit Diagram ( CR5 Mater
10、ial),一个合格的分析应变结果是在成型极限范围内 A robust Stamping process is one in which strains in part lies well with in the forming limit diagram.,成型分析相关标准 Formability Analysis Relate Standard,成型分析相关标准 Formability Analysis Relate Standard,材料变薄：Thinning 板料在拉延过程中受主副应力的作用产生相应的主副应变，板料逐渐变薄，拉延出产品形状。在成型分析时，我们根据材料的等级、厚度、性能对其
11、变薄率进行控制，通用标准根据材料类型对材料的最大变薄率作出了限定，标准如下： There are major stress and minor stress in drawing operation , so the steel thinning to shape the product curve . In formability analysis operation , according to gradethicknessmechanics of material to control thinning , GM maximum thinning limit standard :,过度变
12、薄会造成制件缩颈、开裂缺陷。 Excess thinning will caused neckingcracking .,成型分析相关标准 Formability Analysis Relate Standard,起皱：wrinkle 在成型过程中，板料在凸凹模之间是自由状态时出现起皱。 Material is freed between the punch and the die during forming. 在翻边和整形工序中，压料力不足或模具圆角过大导致制件角部出现起皱。 Suppressing pressure is not sufficient or the die radius
13、is too large in a cone shape during flange and restrike operation .,通用标准：GM standard 在距拉延到底3mm工序件的外表面、密封面、配合面、基准面区域无可视起皱和波浪。 No visual wrinkles and waviness on show surfaceseal surfacemating surfacedatum surface in visual check for break down panel of 3 mm off bottom 板料增厚5%区域无可视起皱。 No visual wrinkle
14、s in the area of thicking 5% .,成型分析相关标准 Formability Analysis Relate Standard,滑移线和冲击线：skid & impact lines滑移线是由产品的弯曲圆角造成的，冲击线是由模具圆角造成的。 Skid line results from bending from product radius, impact line results from die radius. 通用标准： GM Standard 1.滑移线冲击线控制在弯曲圆角范围内，不可出现在外表面上。Skid and impact lines position
15、 must be within bend radius area, no occure on the surface. 2.滑移线R角区域的接触压力小于材料屈服强度的15%。Contact pressure of skid line area 1mm must not exceed 1 mm from the nominal in free state. 2.零件料厚小于等于1mm，其自由状态回弹量控制在2mm以内。Part with thickness = 1mm must not exceed 2 mm fromthe nominal in free state. 3.质量目标：制件轮廓公差在+-0.5mm以内的符合率为80%。Quality target : 80% of PIST are less than or equal to +-0.5 mm of nominal,
