某汽车减震器多道次渐进成形数值模拟分析
Numerical Simulation of Multi-step Incremental Sheet Forming for a Car Shock Absorber
刘春达1，胡建标2，刘健1，周杰2，田飞2
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作者单位：1.重庆长安汽车股份有限公司汽车工程研究院，401120；
2.重庆大学材料科学与工程学院，400044
中文关键字：渐进成形；多道次；减震器；数值模拟；
英文关键字：Incremental sheet forming; Multi-step toolpath;Shock absorber;Numerical simulation
中文摘要：渐进成形是一种具有广泛应用前景的新型柔性无模加工技术，但侧壁较陡制件壁厚减薄严重的问题一直制约着其推广应用。本文以某汽车减震器为例，分析零件结构，得出单道次不能成形的结论；于是采用多道次成形，根据成形理论基础，设计加工工艺过程，计算每道次材料的减薄率，提出每次减薄率分别为0.23,0.3,0.46的三道次成形策略。建立有限元模型进行数值模拟，比较分析厚度值，模拟厚度结果符合工艺设计最小壁厚0.7mm的要求。证明了某汽车减震器多道次渐进成形方案设计的正确性，为渐进成形在侧壁较陡制件的推广应用及多道次的工艺设计提供了一定的理论依据。
英文摘要：Incremental sheet forming(ISF) is a novel, flexible and dieless sheet forming process with extensive useful perspective, however, serious thinning problems of somewhat steep sidewalls limited its spread application. This paper analysed a car shock absorber structure, and got the answer that this part can't be made by one-step forming process. Then according to multi-step forming theory, designed forming process, calculated each step's thinning, three-step toolpath method with each thinning of 0.23,0.3,0.46 was proposed. Finite element method model was built to undergo numerical simulation, and the result showed that the numerical simulation thickness matched the propose designed requirement by a minimum thickness of 0.7mm. This confirms the validity of the proposed designed multi-step toolpath process, and supplied the theory base for ISF's application in somewhat steep sidewall parts and designing process in mulit-step toolpath