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

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

Received：2022-12-07

Revised：2023-09-28

Online：2024-04-08

Stamping test and simulation analysis of shock absorber mounting end (Online)

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