蒋磊 李十全 王龙 王大鹏

摘要：为了减少汽车翼子板冲压模具工序数量，降低汽车翼子板制造成本，以某SUV车型翼子板为研究对象，在分析产品冲压工艺的基础上，提出了一种采用工序集成技术的三工序冲压方案。通过将侧冲孔与侧翻边整形复合，并对大角度、长法兰翻边采用一次侧整形工艺，实现了翼子板侧冲孔、侧翻边、侧整形等不同工艺内容的同序化。介绍了满足翼子板三工序要求的翻边整形模结构，阐述了三种不同类型的特殊斜楔机构的结构布局和工作原理。最终完成了三工序化翼子板的工业化应用，达到了批量生产的要求。研究结果表明，三工序冲压方案能够有效缩短翼子板冲压工序，大幅削减翼子板的生产成本。

关键词：翼子板；三工序；工序集成；冲压工艺；模具结构；特殊斜楔

中图分类号：TG 385； U 466 文献标志码：A

基金项目：东风本田新车型研发项目（151N2HXNME01）

Design of Flanging-shaping Die for Automobile Fender Based on Three-process

JIANG Lei， LI Shiquan， WANG Long， WANG Dapeng（Dongfeng Honda Automobile Co.， Ltd.， Wuhan 430056， China）

Abstract： In order to reduce the number of automotive fender stamping die processes and cut the manufacturing cost of automobile fender， the fender of an SUV was taken as the research object. Based on the analysis of product stamping technology， a three-process stamping scheme using process integration technology was proposed. By combining the side punching and side flanging-shaping and adopting the primary side shaping process for large angle and long flange flanging， the same sequence of different process contents， including wing side punching， side flanging， side shaping and so on， was realized. The structure of flanging-shaping die meeting the three-process requirements of fender was introduced， and the structure layout and working principle of three different types of special-wedge mechanisms were described. Finally， the industrial application of three-process fender was completed and the requirements for mass production was achieved. The results show that the three-process stamping scheme can effectively shorten the fender stamping process， and greatly reduce the production cost of fender.

Keywords： fender； three-process； process integration； stamping process； die structure； special wedge

沖压作为目前汽车覆盖件最主要的加工方式，在整个汽车制造链中的作用不可或缺，而实现冲压加工离不开冲压模具。由于汽车覆盖件结构复杂、轮廓尺寸大、质量要求高，导致用于生产汽车覆盖件的冲压模具难以实现工序内容的高度集成化。以顶盖、地板、翼子板、侧围外板、四门两盖等汽车主机厂常规自制冲压件为例，这些汽车覆盖件的冲压模具基本以四工序为主，个别成形难度大的汽车覆盖件甚至需要五工序冲压模具来完成生产[1-3]。过多的工序不仅造成了巨额的冲压模具投资浪费，还拉长了汽车覆盖件冲压生产链，从而阻碍生产效率的提升和加工成本的控制。……