张博强,李宗瑾,赵浩翰,等. 减振器安装端头的冲压成型试验与仿真分析[J].河南理工大学学报(自然科学版)，doi:10.16186/j.cnki.1673-9787. 2022120016

ZHANG B Q,LI Z J,ZHAO H H,et al．Stamping test and simulation analysis of shock absorber mounting end［J］.Journal of Henan Polytechnic University( Natural Science) ，doi:10.16186/j.cnki.1673-9787. 2022120016

减振器安装端头的冲压成型试验与仿真分析(网络首发)

张博强¹，李宗瑾¹，赵浩翰²，陈国强³，金鑫⁴

（1. 河南工业大学 机电工程学院，河南 郑州 450001；2. 燕山大学 机械工程学院，河北 秦皇岛 066004；3. 河南理工大学 机械与动力工程学院，河南 焦作 454000；4. 宇通重工股份有限公司，河南 郑州 450001）

摘要: 目的 为了降低减振器安装端头的开发难度，减少模具加工设计中遇到的问题，方法 选取某一减振器安装端头的主板体和外套管为研究对象，利用Dynaform软件进行数值模拟，针对主板体成型选取对其成型质量影响较大的摩擦因数、合模速度、拉延速度和模具间隙为主要因素设计正交试验，以最大减薄率为评价指标求解主板体成型最优冲压工艺参数组合；针对外套管成型采用提前刺破的方法对其成型质量进行优化，并对实际生产的安装端头进行力学、厚度和气密性测试。结果 研究获得主板体成型的最优冲压工艺参数组合即摩擦因数为0.145，合模速度为2 000 mm/s，拉延速度为1 000 mm/s，模具间隙为2.1 mm。在此基础上进行数值模拟和生产验证。数值模拟中主板体最大减薄率为17.175%，最大增厚率为53.061%；外套管最大减薄率为13.770%，最大增厚率为58.320%，符合设计要求。生产试验中，力学测试过程中端头表面质量良好，未发生变形、明显起皱和开裂等现象；厚度测试中端头的试验壁厚与模拟壁厚最大偏差为6.8%，和数值模拟结果基本一致；气密性测试中，在内部冲压1.6 MPa，静置30 s情况下，端头未出现漏气现象。结论 研究表明，安装端头的综合性能达到要求，验证了端头成型中工序设置顺序的正确性。研究结果可为减振器安装端头的研发提供一定的理论指导。

关键词: Dynaform；减振器安装端头；数值模拟；参数优化；正交试验

doi:10.16186/j.cnki.1673-9787. 2022120016

基金项目: 国家自然科学基金资助项目（U1304525）；河南省科技研发计划联合基金资助项目（222103810086）

收稿日期：2022-12-07

修回日期：2023-09-28

网络首发日期：2024-04-08

Stamping test and simulation analysis of shock absorber mounting end

ZHANG Boqiang ¹, LI Zongjin ¹, ZHAO Haohan ², CHEN Guoqiang ³, JIN Xin ⁴

(1. School of Mechanical and Electrical Engineering, Henan University of Technology, Zhengzhou 454001, Henan, China；2. School of Mechanical Engineering, Yanshan University, Qinhuangdao 454003, Hebei, China；3. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000, Henan, China；4. Yutong Heavy Industries Co., Ltd., Zhengzhou 450001, Henan, China)

Abstract: Objectives In order to reduce the development difficulty of the shock absorber installation end and the problems encountered in the mold processing design．Methods The main plate body and outer sleeve of the installation end of a shock absorber were selected as the research objects, and the numerical simulation was carried out by Dynaform software. The friction coefficient, clamping speed, drawing speed and die clearance, which had great influence on the forming quality of the main plate body, were selected as the main factors to design the orthogonal test. The maximum thinning rate was used as the evaluation index to solve the optimal stamping process parameter combination of the main plate body forming. The forming quality of the outer sleeve was optimized by the method of early puncture. The mechanics, thickness and air tightness of the actual production installation end are tested．Results The optimal combination of stamping process parameters for the main plate forming is obtained, that is, the friction coefficient is 0.145, the closing speed is 2 000 mm / s, the drawing speed is 1 000 mm / s and the die clearance is 2.1 mm. On this basis, numerical simulation and production verification are carried out. In the numerical simulation, the maximum thinning rate of the main plate is 17.175 %, and the maximum thickening rate is 53.061 %. The maximum thinning rate of the outer sleeve is 13.770 %, and the maximum thickening rate is 58.320 %, which meets the design requirements. In the production test, the surface quality of the end is good during the mechanical test, and there is no deformation, obvious wrinkling and cracking. The maximum deviation between the experimental wall thickness and the simulated wall thickness of the end in the thickness test is 6.8 %, which is basically consistent with the numerical simulation results. In the air tightness test, there was no air leakage at the end under the condition of internal stamping of 1.6 MPa and standing for 30 s．Conclusions The research shows that the comprehensive performance of the installation end meets the requirements, and the correctness of the process setting sequence in the end forming is verified. The research results can provide some theoretical guidance for the research and development of shock absorber installation end.

Key words: Dynaform; shock absorber installation end; numerical simulation; parameter optimization; orthogonal test