Core Technologies of Die at the present stage

Presentation on theme: "Core Technologies of Die at the present stage"— Presentation transcript:

1 Core Technologies of Die at the present stage
模具现阶段的核心技术 Core Technologies of Die at the present stage

2 Mold Surface Engineering
模面技术 Mold Surface Engineering

3 两个目标： Two targets： 1. 提高制件的品质 。 Improve the quality of the parts. 2. 缩短模具制造周期。 Shorten the die manufacturing cycle.

4 保证成型方面所作模面处理内容 Die surface treatment to improve the formability

5 模面处理内容 Mold surface treatment
模面处理内容－1.1 特征棱线的不等间隙 处理内容描述 Description 1.1特征棱线区域的不等间隙 Unequal die gap treatment for the characteristic line area. a.棱线附近着色不实，会导致棱线不清晰等质量问题 Coloring is difficult in the characteristic line area, it will cause quality problems such as characteristic line is not clear. HOOD OTR 特征棱线压紧 Make small die gap in the characteristic line area DOOR OTR 特征棱线压紧 Make small die gap in the characteristic line area

6 模面处理内容 Mold surface treatment
模面处理内容－1.2 反成型特征的不等间隙 处理内容描述 Description 1.2反成形特征区域的不等间隙 Unequal die gap treatment for the reverse forming area. a.反成型区域着色不实，所引起制件表面质量问题 Coloring is difficult in the reverse forming area, it will cause surface low. b.反成形处的棱线不清晰 Characteristic line is not clear in the reverse forming area. 反成形区域压紧 Make small die gap in the reverse forming area. TAIL GATE OTR HOOD OTR 反成形区域压紧 Make small die gap in the reverse forming area.

7 模面处理内容 Mold surface treatment
模面处理内容－1.3 合边面和搭接面的不等间隙 处理内容描述 Description 1.3合边或装车时的搭接面的不等间隙 Unequal die gap treatment for the lap joint surface. a.保证了搭接面和装车基准面等重要部位尺寸精度 Ensure the size accuracy for the important surface of the parts, such as lap joint surface and datum surface. b.相应冲孔位置的压紧确保了冲孔位置的精度 Make small die gap in the hole area to ensure the hole position precision. HOOD INR 搭接面压紧 Make small die gap for the lap joint surface 搭接面压紧 Make small die gap for the lap joint surface TAIL GATE OTR

8 模面处理内容 Mold surface treatment
模面处理内容－1.4.1 制件缺陷区域凹型压紧 处理内容描述 Description 1.4制件易出现缺陷的区域凹型压紧 Make small die gap in the area where surface defect easy appears. 拉延后的塌陷以及圆角鼓凸等影响外板件的表面质量 Surface wave after drawing affects the quality of outside panels. 易出现面品问题处压紧 Make small die gap in the area where surface defect easy appears. FENDER 易出现面品问题处压紧 Make small die gap in the area where surface defect easy appears. SUN ROOF

9 补偿模具结构变形方面所作模面处理内容 Die surface treatment to compensate the die deformation

10 结构分析内容－1.5.2 模具结构变形导致着色困难：后背门外板
结构分析内容 Structure analysis 结构分析内容－1.5.2 模具结构变形导致着色困难：后背门外板 处 理 内 容 描 述 Description 由于模具结构的变形导致的着色困难－后背门外板 Die deformation results in die surface coloring difficult.-Backdoor-Outer 凹模型面结构分析结果 The result of die surface structure analysis . Z 向位移等值线云图 Isoline plot of displacement in Z direction. 凹模型面模面处理结果 The result of die surface treatment. 凹模型面做紧云图 Plot of making small die gap.

11 结构分析内容－1.5.2 模具接触压应力：后背门外板
结构分析内容 Structure analysis 结构分析内容－1.5.2 模具接触压应力：后背门外板 处 理 内 容 描 述 Description 1.2 模具结构分析结果的判别 Distinguish of the die structure analysis result. 凹模最大接触压应力为356MPa，下图显示的是0～60MPa的应力等值线云图，模具型面区域的变形达0.2mm以上，模具本体的变形最大可达0.5mm。判断研合时是否着色仍需要对接触压力的应用。 The max die contact pressure is 356MPa. The picture below shows 0~60MPa of the pressure isoline plot. The die surface deformation is over 0.2mm, and the max die deformation can be 0.5mm. Contact pressure should be taken into account to distinguish the coloring while polishing. 凹模型面接触压应力云图 Contact pressure plot of die surface

12 结构分析内容 Structure analysis
结构分析内容－1.5.6 侧向力的描述 处 理 内 容 描 述 Description 1.3 侧向力的描述 Description of lateral force 模具的侧向力有两种表现方式：一种是由于小面积的接触，接触压力致使模具沿着此处的压力方向移动；另一种是由于比较平缓的大面接触，所导致模具沿此处型面产生微小滑动而产生的侧向移动。 如下图所示： There are two types of lateral force. First, the contact area is small, the die moves along the stress direction because of the contact pressure. Second, the contact surface is big and gentle, the die moves along the surface slightly, and it leads to the lateral movement. As shown in the picture below: 大面接触滑动引起侧向力 Lateral force caused by slide of big surface contact 此处斜面接触引起侧向力 Lateral force caused by inclined surface contact DOOR OTR T/LID OTR 侧向力方向 Direction of lateral force 侧向力方向 Direction of lateral force

13 结构分析内容 Structure analysis
结构分析内容－1.5.6 关于侧向力的结构分析结果 处 理 内 容 描 述 Description 1.3 根据机床滑块和上模的位移方向，提前预模具侧向力的方向。 According to the slide block and the direction of the movement of upper die, predict the direction of the mold lateral force in advance. A 行李箱外板结构分析结果（位移云图） Structure analysis result of trunk outer (Movement nephogram) SEC A－A 的总位移方向 Movement direction of SEC A-A

14 模面处理内容－1. 6.1 压边圈的不等间隙：发动机盖外板
模面处理内容——压边圈 Die surface treatment----Binder 模面处理内容－ 压边圈的不等间隙：发动机盖外板 处 理 内 容 描 述 Description 2. 1 压边圈的不等间隙处理－机盖外板 Unequal die gap treatment of blankholder----Hood outer 四角让空 Make big die gap in the four corner area of the blankholder. 结构变形的补偿 Compensation of the structure deformation 主要功能部位的补偿 Compensation of the main function part L＝30～60 A－A视图 SEC A-A 上模 Upper die 板料 Blank 压边圈 Blankholder A A 凹型筋让空 Make big die gap for the lower drawbead L

15 模面处理内容－1. 6.2 压边圈的不等间隙：行李箱外板
模面处理内容——压边圈 Die surface treatment----Binder 模面处理内容－ 压边圈的不等间隙：行李箱外板 处 理 内 容 描 述 Description 2. 2 压边圈的不等间隙处理－行李箱外板 Unequal die gap processing of blankholder----Trunk outer A－A视图 SEC A-A 间隙值渐变 Gap value gradient A 主要功能部位的补偿 Compensation of the main function part 倾斜让空 Make big die gap in the way of inclined surface

16 模面处理内容－1. 6. 3 压边圈的不等间隙和结构分析结果：左/右前翼子板
模面处理内容——压边圈 Die surface treatment----Binder 模面处理内容－ 压边圈的不等间隙和结构分析结果：左/右前翼子板 处 理 内 容 描 述Description 2.3 压边圈的不等间隙处理－左/右前翼子板 Unequal die gap processing of blankholder----LH/RHFender 根据现场数据总结的翼子板压边圈处理方法与结构分析的对应 According to the data of fender binder work on line,corresponding to structure ansys 目标：以压边圈的结构分析为基础,进行细化的模面补偿。 goal:It is based on structure ansys of binder to refine compensation 翼子板压边圈模面补偿 fender binder compensation by MSE 主要功能部位的补偿 compensation in main function 间隙值渐变 gap gradual change 打斜让空 make gap large 结构分析结果－接触压应力 翼子板压边圈 Structure ansys result-contact pressure fender binder

17 Mold Surface engineering treatment reduce polishing
减少研合区域所作模面处理内容 Mold Surface engineering treatment reduce polishing

18 处 理 内 容 描 述 describe work content
模面处理内容Mold Surface Engineering work content 模面处理内容－ 拉延工艺补充的让空 处 理 内 容 描 述 describe work content 拉延序工艺补充的让空 Make the abundant of CAE model gap large in drawing operation 修边线trimming line 凹模拉延立面让空make upper die gap large 工艺补充让空 make the abundant gap large A T/LID OTR 补充面让空0.2mm make the gap 0.2mm larger SEC A－A示意图

19 处 理 内 容 描 述 describe work content
模面处理内容Mold Surface Engineering work content 模面处理内容－ 制件大平面的挖空 处 理 内 容 描 述 describe work content 制件大平面的挖空处理 big flat surface hollows work 由于制件靠凸型成型，为减少研合区域，对诸如顶盖、机盖等存在大平面的区 域进行挖空。because of the part deform by lower die,for reduce adjust the gap area,so deal with hollows in big flat surface, for example, roof, hoodouter and so on. 对于顶盖挖空量从2mm增加到铸造挖空，从而减少原材料和机加工的消耗。 如下图所示，经客户同意，顶部凹型可挖空。For the roof,the hollow is from 2mm to hollow in cast,thus reduce raw material and machining cost.Look at the following picture,Agreement with the customer.The upper die could deal with hollow work. 大平面让空 局部有特征 SUN ROOF 大平面让空 HOOD OTR big flat surface hollows big flat surface hollows

20 处 理 内 容 描 述 describe work content
模面处理内容Mold Surface Engineering work content 模面处理内容－后序压料芯的不等间隙 处 理 内 容 描 述 describe work content 后序压料芯功能部位的不等间隙 the pad useful function area unequal gap in later operation 下图为某一翼子板修边序不等间隙图例：the below picture is show fender trimming operation unequal gap 间隙值gap（mm） t + 2 t t－0.05 颜 色 color t－0.08 t－0.1 t－0.1以上 FENDER PAD DIE

21 Full process press simulation
全工序冲压仿真模拟 Full process press simulation

22 全工序仿真模拟的流程 full process simulation flow
以背门内板为例，其工艺设计内容为：OP10—开卷落料；OP20—拉延；OP30—修边、冲孔；OP40—修边、冲孔；OP50—翻边整形。其多工步仿真设置流程为： As backdoor inner example,the CAE process is: op10-Blanking; op20-drawing; op30-trimming、pirec e; op40-trimming、pirec e; op50-flange、restrike. The full process simulation setting: （1）、OP10，BLANKING （2）、OP20，GRAVITY,CLOSING,DRAWING （3）、OP30，SPRINGBACK,LOCATING,CLOSING,CUTTING （4）、OP40，SPRINGBACK,LOCATING,CLOSING,CUTTING,FORMING （5）、OP50，SPRINGBACK,LOCATING,CLOSING,CUTTING,FORMING （6）、CHECK ON FIXTURE，SPRINGBACK WITH GRAVITY OP20—拉延 draiwng OP30—修边，冲孔trimming pirece OP40—修边，冲孔trimming pirece OP50—翻边整形flange restrike OP10—开卷落料Blanking

23 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect 确认仿真过程每一工步的工具动作内容正确，板料动作合理，无不良现象发生。主要需要考虑一下几点（1），拉延序的工具运动过程，重力、闭合、以及拉延到板料的状态；（2）后序的符型区域、符型状态、闭合后板料的状态以及翻边整形过程。 Making the tools moving in every operation is right,the blank moving right,all the things is OK,we should main consider the flowing points: 1,the tools moving in drawing process,gravity,closing,and blank status in the end of drawing. 2,the fitting area in the following operation、the blank fitting status、 the status of closing、and the process of flange or restrike. 还是背门内板为例，工序排布为OP20—拉延，OP30—修冲，OP40—修冲，OP50—翻边整形，介绍仿真结果过程检查内容。 Also as backdoor inner example,the CAE process is: op10-Blanking; op20-drawing; op30-trimming、pirec e; op40-trimming、pirece; op50-flange、restrike.introduce the main check content in the process of simulation.

24 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect A) 断面检查拉延过程：工具运动是否合理，工具是否存在穿透板料，压边圈合拢位置是否正确，上模运动是否到底。 A) section check in the process of drawing:tools moving right or not,tools exist penetration or not;closing right or not;upper die move to the end or not. 闭合状态断面检查 closing check 重力状态断面检查 gravity check 拉延到底断面检查 the end of drawing check

25 fitting status is not good
全工序仿真模拟的流程 full process simulation flow 仿真过程合理性检查 the process of simulation inspect B) OP30修冲序检查内容：修冲序主要是检查两个状态，符型状态和压料后状态。 符型状态:符型必须良好，这是零件本工序能够稳定定位的前提，也是制件在压料过程中避免发生附加塑形变形的前提。如果制件不能良好符型，则需要检查干涉位置，设法解决干涉问题。 B) OP30 trimming and pirece check content:the operation main check two status,fitting and after closing status。 Fitting:Fitting must be good，it is make the part to maintain stable in the operation in advance,also in the closing process avoid the part has plastic deformation.If fitting is not good ,we shuold check why ,and do our best to solve it. 零件part 下模面lower die surface 符型状态不好，立壁干涉 fitting status is not good

26 板料功能区附型情况（板料到下模面的距离）
全工序仿真模拟的流程 full process simulation flow 仿真过程合理性检查 the process of simulation inspect A A A-A 符型良好fitting good，OK 板料功能区附型情况（板料到下模面的距离） the blank fitting in useful function (the distance is blank to lower die)

27 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect 压料状态：压料状态主要考虑压料完成后制件是否发生了塑形变形。由于压料工具是由力控制的，且现场调试时只会研合功能区域，所以一般认为压料过程中零件是不会发生塑形变形的，或者只会有少许的塑形变形。检查压料前后，制件的塑形变形，或者查看闭合过程的塑性应变率。 Closing status：Closing status is main consider the blank after closing has plastic deformation or not,The closing tools are controled by force,and debug on line just can polish useful function areas.so general think the part could not have plastic deformation or have less plastic deformation after closing.So check the blank from begin close to finish close plasic deformation,or check the rate of change plastic strain during closing. 压料之后塑形应变 plastic strain after closing 压料之前塑形应变 plastic strain before closing

28 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect C) OP40修冲序检查内容：检查内容和OP30相同，符型状态和压料后状态。 C) OP40 trimming and pirece check contect:It is the same to OP30,fitting and after closing status。 符型状态 fitting 压料之前塑形应变 plastic strain before closing 压料之后塑形应变 plastic strain after closing

29 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect D) OP50 翻边整形检查内容： 首先，检查附型情况。翻边整形类的模具的附型不同于修冲序，某些情况下考虑治理回弹的需要，不能做到完全附型，但一般不会差别太大，一般距离下模型面控制在2mm以内，辅助制件定位装置，确保制件定位准确。 其次，压料前后制件塑形应变不存在大的差异。 D) OP50 flange and restrike content:First,check the fitting.Flange operation is different from trimming operation,in some times,we should think springback compensation,so it can not complete fitting,but the difference is not very big,in general ,the distance to lower die should be in 2mm,the locating pin could make the part right. second,between the first and the end closing,plastic strain do not have big distance. 符型状态 fitting 压料之前塑形应变 plastic strain before closing 压料之后塑形应变 plastic strain after closing

30 全工序仿真模拟的流程 full process simulation flow
仿真过程合理性检查 the process of simulation inspect E) 检测状态检查check the status of inspection 检测实际是模拟制件在检具或其它支撑装置上的回弹过程。检查内容有确认制件夹持及定位方式为GD&T所指定位置，制件放置方位与实际相同（主要是考虑重力方向的影响）。 Inspection is simulate springback of the part on fixture or other equipment in fact.Make sure the clamp area is show by GD&T.Make the part is in the real condition(main consider the influence of gravity). 检具的检测状态 the status on fixture 检具上的回弹 springback on fixture

31 full process simulation example
全工序冲压仿真模拟案 例 展 示 full process simulation example

32 制件的全工序模拟及回弹补偿full process simulation and springback compensation
白光扫描 符形验证 white light scan and fitting check 现场照片 the real part picture

33 机盖外板的回弹预测及补偿---材料铝合金
Hood outer springback prediction and compensation---aluminium alloy

34 机盖外板的回弹预测及补偿---材料铝合金
Hood outer springback prediction and compensation-aluminium alloy

35 级进模 Progressive dies (30~50SPM)

36 级进模 Progressive dies

37 铝板制件 Aluminum parts

38 客户 References

39 热成型 Hot Forming

40 热成型模具冷却系统的开发 Development of die cooling system
热成型模具开发 Development of Hot Forming Tooling 热成型模具冷却系统的开发 Development of die cooling system 深钻孔 Deep Drill 壳式水路 Shell system

41 热成型模具冷却水道仿真模拟 Cooling channel simulation
热成型模拟 Hot Forming Simulation 冷却水流速分布 Water velocity distribution 冷却水压力分布 Water pressure

42 Simultaneous Engineering
同步工程 Simultaneous Engineering

43 SE——冲压分析Simultaneous Engineering press ansys

44 SE——冲压工序图 Simultaneous Engineering press operation chart

45 SE——3D layout 和模拟源文件 Simultaneous Engineering 3D layout and simulation file
提供3D layout（UG或Catia) 和全工序模拟源文件(Autoform R3.1) provid 3D layout and full process simulation file(Autoform R3.1)

46 SE——制件及工装开发明细 Parts and development details
冲压SE后提供的明细，包括工序和模具数量，预估坯料尺寸，模具尺寸，落料样板，材料利用率，成型力，生产线排布，冲压件开发分类SE provide details include operation and the number of dies,preliminary evaluate dimension of blank and dies ，material use ratio,total force,product lines,and classify of the parts.

47 谢 谢 Thanks