李军

摘 要：从理论和外形特征对曲面翻边成形工艺重新进行组合和分类，归纳和总结了六种翻边类型，基本上涵盖了汽车钣金件中常见的曲面翻边形式。对六种曲面翻边类零件进行三维建模并定义相关的外形几何参数，对其中的四种曲面曲线翻边类型进行数值模拟，对每种零件数值模拟的成形过程和成形极限进行分析研究。根据分析研究的结果，合理地布置和使用拉延筋使零件的成形质量得到进一步的提高和改善，总结拉延筋对翻边成形后变形区最大主应变和其分布位置的影响规律，并结合试验对数值模拟的结果进行验证。对于拉延筋在曲面翻边类零件的实际生产中具有很好的参考作用。

关键词：翻边类型；翻边成形；数值模拟；拉延筋

中图分类号：TG386文献标文献标识码：A文献标DOI：10.3969/j.issn.2095-1469.2015.06.08

Abstract：Based on the theory and the shape characteristics， the surface flanging process was regrouped and classified and 6 types of flanging were summarized， which cover the most common surface flanging of automotive sheet metal. For each type of surface flanging parts， 3D models were constructed and the related geometric parameters were defined. Numerical simulations were conducted for tour types of flanging and then the forming process and forming limit were analyzed. The results show that the optimal arrangement of drawbead can improve the forming quality of parts. The influences of drawbead on the deformation distribution and the maximum principle strain were summarized and the simulation results were verified by the experiments. The paper provides a good reference for production of surface flanging parts using drawbead.

Key words：flange type； flanging； numerical simulation； drawbead

随着汽车行业的飞速发展和生活水平的不断提高，人们对汽车的外形要求越来越高。为满足装配和焊接的要求，大部分车身零件都需要进行翻边成形。在汽车的外形设计中，简单的钣金结构利用传统的成形工艺就可以完成，但很难吸引消费者的眼球。别出心裁的外形设计更能得到消费者的关注（例如国外的一些高档车、概念车等），复杂的汽车钣金结构中曲面曲线翻边类结构较为常见，也是汽车钣金结构设计中较为困难的部分，主要的困难是达不到很好的外观成形条件（主要出现起皱和破裂）。

近年来，国内外学者的研究重点主要集中在钣金零件拉延过程的成形性，而对翻边过程成形的研究相对较少[1-4]。……