聂昕　毛定山　王辉

摘 要：由于机台和模具变形、制件减薄等因素的影响，造成合模时模面间隙与板料成形零件厚度不一致而导致模具研合率低.针对上述问题提出了一种新的模具模面精细化补偿方法，针对该补偿方法提出了一种基于二分法的网格变量映射新算法来实现不同网格变量之间的精确映射.该设计补偿方法在工艺设计阶段即可对模具型面进行相应的变形补偿，以抵消实际模具结构变形对成形件质量的影响.应用实例表明，该映射算法在精度和速度上有较大的提高，该补偿方法能够解决模具调试阶段研合率低的问题， 大大提高了首次合模率.

关键词：网格映射；冲压机台；变形；模面补偿；合模率

中图分类号：TG386.3 文献标识码：A

Abstract：Due to the impact of the elastic deformation of tools and press， and the blank thinning and other factors， the die surface gap is not consistent with the thickness distribution of the stamped part， which leads to low spot rate. With regard to the problem mentioned above， a new mesh mapping algorithm based on binary search was presented， which can realize the accurate mapping between different meshes，and then， a new methodological scheme was developed for the compensation of the die surfaces. In the early design stage， the new methodology can guide the engineer to modify the die surface， thus offsetting the influence on quality caused by the deformation of tools. Application example has shown that the new mapping algorithm not only improves the accuracy but also improves the search speed. The methodology can solve the problem of low spot rate and noticeably improve the first-time contacting ratio.

Key words：mesh mapping； cold forming machines； deformations； die surface compensation； contacting ratio

大型汽车外覆盖件冲压模具的设计制造是汽车制造业的关键技术之一，是制约我国汽车工业发展的一个瓶颈环节.汽车覆盖件是通过模具上下模型腔相互贴合而成形的，因此零件成形质量是由模具型腔保证的.模具主体一般采用铸造成形，为减轻模具重量，模具采用中空的壳体结构，为了安装顶杆支撑压边圈，压机工作台面中间镂空，所以当其受力较大时，压机的挠度变形，模具弹性变形，制件的减薄，这些影响因素最终将导致上下模型腔之间在合模到底时存在不等间隙.传统上主要依靠钳工不断研配修模试模来消除这些因素的影响，严重影响了模具的生产周期.为了缩短……