CN109033512B - A Judgment Method for Optimal Cutting Edge Shape of Fine Blanking Die - Google Patents
A Judgment Method for Optimal Cutting Edge Shape of Fine Blanking Die Download PDFInfo
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Abstract
Description
技术领域technical field
本发明涉及模具制造技术领域,尤其是涉及一种精冲模具最优刃口形状的判定方法。The invention relates to the technical field of die manufacturing, in particular to a method for judging the optimal cutting edge shape of a fine blanking die.
背景技术Background technique
精冲模具刃口通常为圆形刃口,且圆角半径较普通模具圆角半径小很多,精冲模具圆角R约为0.01~0.1mm。The cutting edge of the fine blanking die is usually a circular cutting edge, and the fillet radius is much smaller than that of the ordinary die, and the fillet R of the fine blanking die is about 0.01-0.1mm.
由于精冲模具在服役过程中受到板料的反向作用力较大,且主要集中在模具的刃口部位,模具刃口部位内部最容易萌生裂纹,导致模具失效。为了提升模具寿命,尽可能地减少模具刃口部位的受力、变形,目前优化模具刃口形状主要的方式有两种。一是根据工程师的经验不断修整模具的刃口形状,二是增大模具圆角半径。前一种方法存在一定的风险,不能保证获得稳定的模具寿命,且优化周期较长,可应用的通用性不强。后一种方法容易导致零件毛刺过高。上述问题的共性是无法科学地保证模具刃口形状处于最优状态。Since the fine blanking die is subjected to a large reverse force from the sheet during its service, and it is mainly concentrated on the cutting edge of the die, cracks are most likely to occur inside the cutting edge of the die, resulting in die failure. In order to improve the life of the mold and reduce the force and deformation of the cutting edge of the mold as much as possible, there are currently two main ways to optimize the shape of the cutting edge of the mold. One is to constantly trim the shape of the cutting edge of the mold according to the experience of the engineer, and the other is to increase the radius of the mold fillet. The former method has certain risks, cannot guarantee a stable mold life, and the optimization cycle is long, and the applicable versatility is not strong. The latter method can easily lead to excessive burrs on the part. The commonality of the above problems is that it is impossible to scientifically ensure that the shape of the cutting edge of the die is in an optimal state.
发明内容Contents of the invention
本发明的目的在于克服上述技术不足,提出一种精冲模具最优刃口形状的判定方法,解决现有技术中没有科学判定模具最优刃口形状的技术问题。The purpose of the present invention is to overcome the above-mentioned technical deficiencies, propose a method for judging the optimal edge shape of a fine blanking die, and solve the technical problem in the prior art that there is no scientific determination of the optimal edge shape of a die.
为达到上述技术目的,本发明提供了一种精冲模具最优刃口形状的判定方法,包括如下步骤:In order to achieve the above-mentioned technical purpose, the present invention provides a method for judging the optimal cutting edge shape of a fine blanking die, comprising the following steps:
步骤1,针对某零件设定的初始模具刃口形状,对该零件的精冲加工过程做1次模拟循环,得到精冲加工过程中模具刃口发生塑性变形的区域。Step 1. For the initial die edge shape set for a certain part, a simulation cycle is performed on the fine blanking process of the part to obtain the plastically deformed area of the die edge during the fine blanking process.
步骤2,确定待分析刃口区域,其包括所述发生塑性变形的区域,及向所述发生塑性变形的区域周边延伸的区域。延伸区域不宜过大,为的是保证发生塑性变形的区域都能纳入判定,提高判定的准确性。Step 2, determining the cutting edge area to be analyzed, which includes the area where the plastic deformation occurs, and the area extending to the periphery of the area where the plastic deformation occurs. The extension area should not be too large, in order to ensure that the area where plastic deformation occurs can be included in the judgment and improve the accuracy of judgment.
步骤3,选择如下至少一种判别方法对待分析刃口区域的刃口形状进行判定:刃口形变量判别方法、刃口内应力判别方法以及模具整体受力判别方法。Step 3: Select at least one of the following discrimination methods to determine the edge shape of the edge area to be analyzed: a method for determining the deformation of the cutting edge, a method for determining the internal stress of the cutting edge, and a method for determining the overall force of the mold.
所述刃口形变量判别方法,目的在于保证刃口形状稳定,其包括如下步骤:The method for discriminating the amount of deformation of the cutting edge aims to ensure the stability of the cutting edge shape, and it includes the following steps:
步骤3.1.1,将所述待分析刃口区域投影于直角坐标网格,令所述待分析刃口区域内的网格节点im数量为m,坐标依次为i1(x1,y1,z1)、i2(x2,y2,z2)……im(xm,ym,zm);Step 3.1.1, projecting the cutting edge area to be analyzed on a Cartesian coordinate grid, the number of grid nodes i m in the cutting edge area to be analyzed is m, and the coordinates are i 1 (x 1 , y 1 , z 1 ), i 2 (x 2 , y 2 , z 2 )…i m (x m , y m , z m );
步骤3.1.2,依次计算最新一次模拟循环中刃口部位的节点i的变形量Di,n、刃口部位平均形变量Dn,以及刃口形变量的方差 Step 3.1.2, sequentially calculate the deformation amount D i,n of the node i at the cutting edge in the latest simulation cycle, the average deformation D n of the cutting edge, and the variance of the cutting edge deformation
其中,n表示当前总的模拟循环次数;m表示当前研究的精冲模具刃口部位的节点数量;D1,n、D2,n、…、Dm,n分别表示第n次模拟循环下第1个刃口节点、第2个刃口节点……第m个刃口节点的形变量;Dn为D1,n、D2,n、…、Dm,n的均值,为D1,n、D2,n、…、Dm,n的方差;Among them, n represents the current total number of simulation cycles; m represents the number of nodes at the cutting edge of the fine blanking die currently being studied; D 1,n , D 2,n ,..., D m,n represent the The first edge node, the second edge node...the deformation of the mth edge node; D n is the mean value of D 1,n , D 2,n ,..., D m,n , is the variance of D 1,n , D 2,n ,..., D m,n ;
步骤3.1.3,判断“Dn<D0,且”是否成立,如果为“是”则判定刃口形状满足判别方法中的判定标准,即初步获得模具受塑性变形影响后更新的刃口形状;如果为“否”,则判定刃口形状不满足判别方法中的判定标准;其中,D0为刃口节点变形量平均值的判别标准值,其取值逻辑取决于精冲行业内的模具精度标准,一般不得小于0.01mm,不得大于0.1mm;/>为刃口节点变形量方差的判别标准值,其取值逻辑为D0的5~20%。Step 3.1.3, judge "D n < D 0 , and "Whether it is true, if it is "Yes", it is determined that the shape of the cutting edge meets the judgment criteria in the discrimination method, that is, the shape of the cutting edge that is updated after the mold is initially obtained after being affected by plastic deformation; if it is "No", it is determined that the shape of the cutting edge does not meet the criteria The judgment standard in the judgment method; among them, D 0 is the judgment standard value of the average value of the deformation of the cutting edge node, and its value logic depends on the mold precision standard in the fine blanking industry, generally not less than 0.01mm, not more than 0.1mm; /> It is the discriminative standard value of the variance of the deformation of the cutting edge node, and its value logic is 5-20% of D0 .
所述刃口最大内应力判别方法,目的在于确保刃口集中应力下降且趋于稳定,其包括如下步骤:The method for judging the maximum internal stress of the cutting edge aims to ensure that the concentrated stress of the cutting edge decreases and tends to be stable, and it includes the following steps:
步骤3.2.1,从模拟结果中获得最新一次模拟循环过程中刃口部位的承受的mises等效应力最大值Pn,max,其中,n表示当前总的模拟循环次数;Step 3.2.1, obtaining the maximum mises equivalent stress P n,max of the cutting edge during the latest simulation cycle from the simulation results, where n represents the current total number of simulation cycles;
步骤3.2.2,判断“Pn,max<P0”是否成立,如果为“是”则判定刃口形状满足判别方法中的判定标准,即初步获得模具受塑性变形影响后更新的刃口形状;如果为“否”,则判定刃口形状不满足判别方法中的判定标准;其中,P0是应力判别标准值,其取值逻辑为一个介于模具材料屈服强度与抗拉强度之间的,且接近模具材料屈服强度的数值。Step 3.2.2, judge whether "P n,max <P 0 "is true, if it is "yes", it is determined that the cutting edge shape meets the judging criteria in the judgment method, that is, the updated cutting edge shape after the mold is initially obtained after being affected by plastic deformation ; If it is "No", it is judged that the shape of the cutting edge does not meet the judgment criteria in the judgment method; among them, P 0 is the standard value of stress judgment, and its value logic is a value between the yield strength and tensile strength of the mold material , and is close to the value of the yield strength of the mold material.
所述模具整体受力判别方法,目的在于降低压力机载荷减少能耗,其包括如下步骤:The method for discriminating the overall force of the die is aimed at reducing the load of the press and reducing energy consumption, which includes the following steps:
步骤3.3.1,从模拟结果中获得最新一次模拟循环过程中模具整体受力最大值Fn,max,并统计到目前为止模拟结果中获得的最大模具整体受力Fmax,其中,n表示当前总的模拟循环次数;Step 3.3.1, obtain the maximum overall force F n,max of the mold during the latest simulation cycle from the simulation results, and count the maximum overall force F max of the mold obtained in the simulation results so far, where n represents the current total number of simulation cycles;
步骤3.3.2,判断“Fn,max/Fmax<a”是否成立,如果为“是”则判定刃口形状满足判别方法中的判定标准,即初步获得模具受塑性变形影响后更新的刃口形状;如果为“否”,则判定刃口形状不满足判别方法中的判定标准;其中,a是模具整体受力最大值需满足的下降达标值,其取值逻辑为模具整体受力最大值需满足随着模拟循环次数增多而逐渐下降的趋势,并且此次模具整体受力最大值与此次及此前所有模拟循环中模具整体受力最大值的比值需达到模具整体受力最大值的下降比例标准值,a的取值范围为0.6~0.9。Step 3.3.2, judge whether "F n,max /F max <a" is true, if it is "yes", it is judged that the edge shape meets the judgment standard in the judgment method, that is, the updated edge after the plastic deformation of the mold is initially obtained If it is "No", it is judged that the shape of the cutting edge does not meet the judgment criteria in the discrimination method; where a is the drop standard value that the maximum overall force of the mold needs to meet, and its value logic is that the overall force of the mold is the largest The value needs to meet the trend of gradually decreasing with the increase of the number of simulation cycles, and the ratio of the maximum overall force of the mold to the maximum overall force of the mold in this and all previous simulation cycles must reach the maximum value of the overall force of the mold The standard value of the drop ratio, the value range of a is 0.6~0.9.
步骤4,若刃口形状满足上述任一判别方法中的判定标准,则判定此时的刃口形状为最优模具刃口形状;否则将此时的刃口形状作为新的初始模具刃口形状,返回步骤1。该最优模具刃口形状为多次连续精冲加工后逐渐稳定的刃口形状。Step 4, if the cutting edge shape satisfies the judgment criteria in any of the above-mentioned discrimination methods, then it is judged that the cutting edge shape at this time is the optimal mold cutting edge shape; otherwise, the cutting edge shape at this time is taken as the new initial mold cutting edge shape , return to step 1. The optimal die edge shape is a gradually stable edge shape after multiple continuous fine blanking processes.
步骤5,计算模具刃口磨损,利用有限元软件及如下磨损模型计算模具刃口的磨损情况:Step 5, calculate the wear of the die edge, and use the finite element software and the following wear model to calculate the wear of the die edge:
其中,W为磨损量,K为材料的磨损系数,S为模具平均寿命,P为接触应力,v为滑动速度,H为材料的洛氏硬度;模具刃口磨损的计算是基于模具平均寿命与单次精冲磨损相乘的结果。Among them, W is the amount of wear, K is the wear coefficient of the material, S is the average life of the mold, P is the contact stress, v is the sliding speed, and H is the Rockwell hardness of the material; the calculation of the wear of the cutting edge of the mold is based on the average life of the mold and The result of multiplying the wear of a single fineblanking.
当然,若对于经过前述方法判定后的刃口形状仍不满意,可以继续进入步骤6,根据具体工况,对获得的最优模具刃口形状进行重新设计,即进行二次优化,重新设计的刃口形状需满足确保零件加工质量、刃口形状与计算结果相似程度高、刃口形状圆滑过渡等要求。对最优模具刃口形状进行重新设计后,可返回步骤1,再次经过本方法进行判定。Of course, if you are still unsatisfied with the shape of the cutting edge determined by the above method, you can continue to step 6, and redesign the obtained optimal mold cutting edge shape according to the specific working conditions, that is, perform secondary optimization, and the redesigned The cutting edge shape needs to meet the requirements of ensuring the processing quality of the part, the high similarity between the cutting edge shape and the calculation result, and the smooth transition of the cutting edge shape. After redesigning the optimal mold cutting edge shape, you can return to step 1 and judge through this method again.
作为优选的,所述模拟循环包括精冲冲压过程以及模具回弹过程。Preferably, the simulation cycle includes a fine-blanking stamping process and a die springback process.
作为优选的,所述模拟循环是利用有限元软件实现,在有限元软件中所述模具(即待优化模具部件及板料)设为弹塑性体。Preferably, the simulation cycle is realized by using finite element software, in which the mold (that is, the mold parts and sheets to be optimized) is set as an elastic-plastic body.
作为优选的,所述有限元软件包括Abaqus和/或Deform。Abaqus是一套功能强大的工程模拟的有限元软件,其解决问题的范围从相对简单的线性分析到许多复杂的非线性问题。Abaqus包括一个丰富的、可模拟任意几何形状的单元库。并拥有各种类型的材料模型库,可以模拟典型工程材料的性能,其中包括金属、橡胶、高分子材料、复合材料、钢筋混凝土、可压缩超弹性泡沫材料以及土壤和岩石等地质材料,作为通用的模拟工具,Abaqus除了能解决大量结构(应力/位移)问题,还可以模拟其他工程领域的许多问题,例如热传导、质量扩散、热电耦合分析、声学分析、岩土力学分析(流体渗透/应力耦合分析)及压电介质分析。Deform是一套基于有限元的工艺模拟系统,用于分析金属成形及其相关工业的各种成形工艺和热处理工艺。通过在计算机上模拟整个加工过程,帮助工程师和设计人员:设计工具和产品工艺流程,减少昂贵的现场试验成本。提高模具设计效率,降低生产和材料成本。缩短新产品的研究开发周期。Preferably, the finite element software includes Abaqus and/or Deform. Abaqus is a powerful finite element software for engineering simulation, which can solve problems ranging from relatively simple linear analysis to many complex nonlinear problems. Abaqus includes a rich library of elements that can model arbitrary geometries. And it has various types of material model libraries, which can simulate the performance of typical engineering materials, including metals, rubber, polymer materials, composite materials, reinforced concrete, compressible superelastic foam materials, and geological materials such as soil and rock. In addition to solving a large number of structural (stress/displacement) problems, Abaqus can also simulate many problems in other engineering fields, such as heat conduction, mass diffusion, thermoelectric coupling analysis, acoustic analysis, rock and soil mechanics analysis (fluid penetration/stress coupling analysis) and piezoelectric dielectric analysis. Deform is a finite element-based process simulation system for analyzing various forming processes and heat treatment processes in metal forming and related industries. By simulating the entire machining process on the computer, it helps engineers and designers: design tools and product process, and reduce expensive field test costs. Improve mold design efficiency and reduce production and material costs. Shorten the research and development cycle of new products.
与现有技术相比,本发明的有益效果包括:利用有限元软件模拟某零件加工过程中模具刃口的受力及塑性变形,并加以判定,帮助判别最优刃口形状,其具有通用性强、准确性高、成本低、风险小等优点;可显著减少精冲刃口部位受力、变形,延缓模具失效;符合精冲行业对提高精冲模具寿命和减少能耗损伤的更高要求的趋势。Compared with the prior art, the beneficial effects of the present invention include: using finite element software to simulate the force and plastic deformation of the die edge during the processing of a certain part, and judge it to help determine the optimal edge shape, which has universality Strong, high accuracy, low cost, small risk and other advantages; can significantly reduce the force and deformation of the fine blanking edge, delay the failure of the die; meet the higher requirements of the fine blanking industry for improving the life of the fine blanking die and reducing energy consumption damage the trend of.
附图说明Description of drawings
图1是本发明的流程图;Fig. 1 is a flow chart of the present invention;
图2是未经本发明判定的刃口形状;Fig. 2 is the cutting edge shape not judged by the present invention;
图3是本发明判定后得到的刃口形状。Fig. 3 is the cutting edge shape obtained after the judgment of the present invention.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.
本发明提供的一种精冲模具最优刃口形状的判定方法,其用于对各类常见精冲模具的刃口形状优化以延长模具寿命,该方法利用模拟的方法,通过计算精冲模具多次冲压过程因受力而导致变形且形状逐渐稳定的刃口,依据刃口形变量的判别标准、刃口内应力的判别标准以及模具整体受力的3种判定准则,科学计算出模具的最优刃口形状,从而在保证零件加工精度的前提下减小模具刃口受力,提升模具寿命。The invention provides a method for judging the optimal cutting edge shape of a fine blanking die, which is used to optimize the cutting edge shape of various common fine blanking dies to prolong the life of the die. For the cutting edge that is deformed and gradually stable in shape due to stress in the multiple stamping process, based on the three judgment criteria for the deformation of the cutting edge, the internal stress of the cutting edge, and the overall force of the mold, the optimal die is calculated scientifically. Cutting edge shape, so as to reduce the force on the cutting edge of the mold and improve the life of the mold under the premise of ensuring the machining accuracy of the parts.
具体来说:精冲模具服役过程中刃口受力而导致变形包括2个方面,一是刃口发生塑性变形导致刃口形状发生变化,二是刃口发生磨损导致刃口形状发生变化。刃口塑性变形计算是基于连续地模拟计算精冲模具精冲加工过程中刃口的塑性变形积累,刃口的磨损量计算是基于单次模拟计算精冲模具精冲加工过程中刃口的磨损量与精冲模具平均寿命的乘积。根据刃口形变量、刃口内应力以及模具整体受力的判别标准,计算单次精冲加工过程中或者刃口变形量、或者刃口受内应力、或者模具整体受力判定精冲模具刃口形状是否进入稳定状态,即刃口形变量可忽略不计。将精冲模具刃口塑性变形与磨损量叠加后得到的刃口形状即是最适合该零件的刃口形状。根据需要可在此最优刃口形状基础上重新人为设计。Specifically, the deformation of the cutting edge caused by force during the service of the fine blanking die includes two aspects. One is that the plastic deformation of the cutting edge causes the shape of the cutting edge to change, and the other is that the cutting edge wears and causes the shape of the cutting edge to change. The calculation of the plastic deformation of the cutting edge is based on the continuous simulation calculation of the accumulation of plastic deformation of the cutting edge during the fine blanking process of the fine blanking die, and the calculation of the wear amount of the cutting edge is based on a single simulation calculation of the wear of the cutting edge during the fine blanking process of the fine blanking die The product of the amount and the average life of the fine blanking die. According to the discriminant criteria of edge deformation, edge internal stress and overall force of the die, calculate the edge deformation, or the internal stress of the edge, or the overall force of the die to determine the edge shape of the fine blanking die during a single fine blanking process Whether to enter a stable state, that is, the deformation of the cutting edge is negligible. The edge shape obtained by superimposing the plastic deformation and wear amount of the fine blanking die edge is the most suitable edge shape for the part. It can be artificially redesigned on the basis of the optimal cutting edge shape as needed.
表1列出了精冲模具最优刃口形状在上述刃口形变量的判别标准、刃口内应力的判别标准以及模具整体受力的判别标准下的门槛值的范围。需要说明的是,对于一个实施例来说,门槛值是位于表1所列的范围值中的一个点值。Table 1 lists the range of threshold values for the optimal edge shape of the fine blanking die under the above-mentioned criteria for edge deformation, internal stress of the edge, and overall force of the die. It should be noted that, for an embodiment, the threshold value is a point value within the range listed in Table 1.
表1Table 1
实施例1:通过有限元软件ABAQUS和/或Deform软件执行与上述步骤相对应的流程以对上述表1中的刃口形变量的上述执行形态进行控制,具体过程如下。Embodiment 1: Execute the process corresponding to the above steps by the finite element software ABAQUS and/or Deform software to control the above execution form of the cutting edge deformation in the above Table 1, the specific process is as follows.
步骤1,利用有限元软件对某零件的精冲加工过程做一次模拟循环,模拟循环包括精冲冲压过程以及模具回弹过程,得到精冲加工过程中模具刃口发生塑性变形的区域。刃口形状如图2所示。Step 1. Use finite element software to perform a simulation cycle on the fine blanking process of a certain part. The simulation cycle includes the fine blanking process and the springback process of the die to obtain the plastic deformation area of the die edge during the fine blanking process. The shape of the cutting edge is shown in Figure 2.
步骤2,圈定待分析刃口区域,该区域应既囊括刃口塑性变形区域,又在刃口塑性变形区域基础上略有扩大,以便判定准确。Step 2, delineate the cutting edge area to be analyzed, which should not only include the plastic deformation area of the cutting edge, but also slightly expand on the basis of the plastic deformation area of the cutting edge, so as to judge accurately.
步骤3,选择刃口形变量判别方法对待分析刃口区域的刃口形状进行判定。将所述待分析刃口区域投影于直角坐标网格,令所述待分析刃口区域内的网格节点数量为18,将所述网格节点从有限元软件中导出,它们的节点编号以及坐标如表2所述:Step 3, select the method for judging the amount of cutting edge deformation to judge the cutting edge shape of the cutting edge area to be analyzed. The cutting edge area to be analyzed is projected on a Cartesian coordinate grid, the number of grid nodes in the cutting edge area to be analyzed is 18, and the grid nodes are derived from the finite element software, their node numbers and The coordinates are as described in Table 2:
表2Table 2
步骤4,通过下述模型计算最新一次模拟循环中刃口部位的节点i的变形量Di,1、刃口部位平均形变量D1,以及刃口形变量的方差 Step 4: Calculate the deformation D i,1 of node i at the cutting edge in the latest simulation cycle, the average deformation D 1 of the cutting edge, and the variance of the cutting edge deformation through the following model
经过计算,具体数据为:Di,1如表3所述,D1=7.7μm,; After calculation, the specific data are: D i,1 is as described in Table 3, D 1 =7.7 μm;
表3table 3
根据实际情况选定判断D0=0.85μm,判别“Dn<D0,且/>”不成立,则将此时的刃口形状作为新的初始模具刃口形状,返回步骤1,并重复步骤1~3,如此循环,计算多次精冲加工过程,并不断更新刃口形状,直至更新的刃口形状符合判别标准。Select and judge D 0 =0.85μm according to the actual situation, Discrimination "D n < D 0 , and /> ” is not established, then take the cutting edge shape at this time as the new initial die cutting edge shape, return to step 1, and repeat steps 1 to 3, and so on, calculate the fine blanking process for many times, and update the cutting edge shape continuously until The updated edge shape meets the criteria.
经过6次模拟后,模拟循环中刃口部位的节点i的变形量Di,6如表4所示,刃口部位平均形变量D6=0.84μm,以及刃口形变量的方差符合刃口变形量的判别标准,则判定此时的刃口形状为最适用于该零件的最优模具刃口形状。After 6 simulations, the deformation amount D i,6 of node i at the cutting edge in the simulation cycle is shown in Table 4, the average deformation of the cutting edge D 6 =0.84μm, and the variance of the cutting edge deformation If it meets the criterion of edge deformation, it is judged that the edge shape at this time is the optimal mold edge shape most suitable for the part.
表4Table 4
步骤5,在第6次受塑性变形影响后模具刃口变形的基础上,利用有限元软件及下述磨损模型计算模具刃口的磨损情况:Step 5, on the basis of the deformation of the die edge after the sixth plastic deformation, use the finite element software and the following wear model to calculate the wear of the die edge:
其中,W为磨损量,K为材料的磨损系数,S为模具平均寿命,P为接触应力,v为滑动速度,H为材料的洛氏硬度;模具刃口磨损的计算是基于模具平均寿命与单次精冲磨损相乘的结果,获得了新的刃口形状,如图3所示。Among them, W is the amount of wear, K is the wear coefficient of the material, S is the average life of the mold, P is the contact stress, v is the sliding speed, and H is the Rockwell hardness of the material; the calculation of the wear of the cutting edge of the mold is based on the average life of the mold and The result of multiplication of single fine blanking and wear results in a new cutting edge shape, as shown in Figure 3.
若对于经过前述方法判定后的刃口形状仍不满意,可根据具体工况对最优模具刃口形状进行重新设计,重新设计的最优刃口形状需满足确保零件加工质量、刃口形状与计算结果相似程度高、刃口形状圆滑过渡等要求。对最优模具刃口形状进行重新设计后,可返回步骤1,再次经过本方法进行判定。If you are still unsatisfied with the shape of the cutting edge determined by the above method, you can redesign the optimal mold cutting edge shape according to the specific working conditions. High similarity of calculation results, smooth transition of cutting edge shape and other requirements. After redesigning the optimal mold cutting edge shape, you can return to step 1 and judge through this method again.
实施例2:通过有限元软件ABAQUS和/或Deform软件执行与上述步骤相对应的流程以对上述表1中的刃口形变量的上述执行形态进行控制,具体过程如下。Embodiment 2: The process corresponding to the above steps is executed by the finite element software ABAQUS and/or Deform software to control the above execution form of the cutting edge deformation in the above Table 1, and the specific process is as follows.
步骤1,利用有限元软件对某零件的精冲加工过程做一次模拟循环,模拟循环包括精冲冲压过程以及模具回弹过程,得到精冲加工过程中模具刃口发生塑性变形的区域。刃口形状如图2所示。Step 1. Use finite element software to perform a simulation cycle on the fine blanking process of a certain part. The simulation cycle includes the fine blanking process and the springback process of the die to obtain the plastic deformation area of the die edge during the fine blanking process. The shape of the cutting edge is shown in Figure 2.
步骤2,圈定待分析刃口区域,该区域应既囊括刃口塑性变形区域,又在刃口塑性变形区域基础上略有扩大,以便判定准确。Step 2, delineate the cutting edge area to be analyzed, which should not only include the plastic deformation area of the cutting edge, but also slightly expand on the basis of the plastic deformation area of the cutting edge, so as to judge accurately.
步骤3,选择刃口内应力判别方法对待分析刃口区域的刃口形状进行判定。Step 3, select the edge internal stress discrimination method to determine the edge shape of the edge area to be analyzed.
步骤4,从模拟结果中获得最新一次模拟循环过程中刃口部位的承受的mises等效应力最大值P1,max,具体数据为:P1,max=3051.15MPa;Step 4. Obtain the maximum value of the mises equivalent stress P 1,max on the cutting edge during the latest simulation cycle from the simulation results. The specific data is: P 1,max = 3051.15MPa;
根据实际情况选定判断P0=2200MPa;判别“P1,max<P0”不成立,则将此时的刃口形状作为新的初始模具刃口形状,返回步骤1,并重复步骤1~3,如此循环,计算多次精冲加工过程,并不断更新初始模具刃口形状,直至更新的刃口形状符合判别标准。Select and judge P 0 = 2200MPa according to the actual situation; judge that "P 1,max <P 0 "is not established, then use the cutting edge shape at this time as the new initial mold cutting edge shape, return to step 1, and repeat steps 1~3 , and so on, calculate multiple fine blanking processes, and continuously update the initial die edge shape until the updated edge shape meets the criteria.
经过6次模拟后,模拟循环中刃口内应力Pn,max如表5所示,刃口内应力P6,max=2177.55MPa,符合刃口内应力的判别标准,则判定此时的刃口形状为最适用于该零件的最优模具刃口形状。After 6 simulations, the internal stress P n,max of the cutting edge in the simulation cycle is shown in Table 5, and the internal stress P 6,max of the cutting edge is 2177.55MPa, which meets the criteria for determining the internal stress of the cutting edge. The optimum die edge shape for the part.
表5table 5
步骤5,在第6次受塑性变形影响后模具刃口变形的基础上,利用有限元软件及下述磨损模型计算模具刃口的磨损情况:Step 5, on the basis of the deformation of the die edge after the sixth plastic deformation, use the finite element software and the following wear model to calculate the wear of the die edge:
其中,W为磨损量,K为材料的磨损系数,S为模具平均寿命,P为接触应力,v为滑动速度,H为材料的洛氏硬度;模具刃口磨损的计算是基于模具平均寿命与单次精冲磨损相乘的结果,获得了新的刃口形状,如图3所示。Among them, W is the amount of wear, K is the wear coefficient of the material, S is the average life of the mold, P is the contact stress, v is the sliding speed, and H is the Rockwell hardness of the material; the calculation of the wear of the cutting edge of the mold is based on the average life of the mold and The result of multiplication of single fine blanking and wear results in a new cutting edge shape, as shown in Figure 3.
若对于经过前述方法判定后的刃口形状仍不满意,可根据具体工况对最优模具刃口形状进行重新设计,重新设计的最优刃口形状需满足确保零件加工质量、刃口形状与计算结果相似程度高、刃口形状圆滑过渡等要求。对最优模具刃口形状进行重新设计后,可返回步骤1,再次经过本方法进行判定。If you are still unsatisfied with the shape of the cutting edge determined by the above method, you can redesign the optimal mold cutting edge shape according to the specific working conditions. High similarity of calculation results, smooth transition of cutting edge shape and other requirements. After redesigning the optimal mold cutting edge shape, you can return to step 1 and judge through this method again.
实施例3:通过有限元软件ABAQUS和/或Deform软件执行与上述步骤相对应的流程以对上述表1中的刃口形变量的上述执行形态进行控制,具体过程如下。Embodiment 3: Execute the process corresponding to the above steps through the finite element software ABAQUS and/or Deform software to control the above execution form of the cutting edge deformation in the above Table 1, the specific process is as follows.
步骤1,利用有限元软件对某零件的精冲加工过程做一次模拟循环,模拟循环包括精冲冲压过程以及模具回弹过程,得到精冲加工过程中模具刃口发生塑性变形的区域。刃口形状如图2所示。Step 1. Use finite element software to perform a simulation cycle on the fine blanking process of a certain part. The simulation cycle includes the fine blanking process and the springback process of the die to obtain the plastic deformation area of the die edge during the fine blanking process. The shape of the cutting edge is shown in Figure 2.
步骤2,圈定待分析刃口区域,该区域应既囊括刃口塑性变形区域,又在刃口塑性变形区域基础上略有扩大,以便判定准确。Step 2, delineate the cutting edge area to be analyzed, which should not only include the plastic deformation area of the cutting edge, but also slightly expand on the basis of the plastic deformation area of the cutting edge, so as to judge accurately.
步骤3,选择模具整体受力判别方法对待分析刃口区域的刃口形状进行判定。Step 3, select the overall force judgment method of the mold to judge the cutting edge shape of the cutting edge area to be analyzed.
步骤4,通过下述模型计算最新一次模拟循环中模具整体受力最大值F1,max,并统计到目前为止模拟结果中获得的最大模具整体受力Fmax;具体数据为:F1,max=636.28kN;Fmax=636.28kN。Step 4, calculate the maximum overall force F 1,max of the mold in the latest simulation cycle through the following model, and count the maximum overall force F max of the mold obtained in the simulation results so far; the specific data is: F 1,max =636.28kN; F max =636.28kN.
根据实际情况选定判断a=0.7;判别“F1,max/Fmax<a”是否成立,如果不成立,则将此时的刃口形状作为新的初始模具刃口形状,返回步骤1,并重复步骤1~3,如此循环,计算多次精冲加工过程,并不断更新刃口形状,直至更新的刃口形状符合判别标准。Select and judge a=0.7 according to the actual situation; judge whether "F 1,max /F max <a" is true, if not, use the cutting edge shape at this time as the new initial mold cutting edge shape, return to step 1, and Repeat steps 1 to 3, such a cycle, calculate the fine blanking process for many times, and continuously update the shape of the cutting edge until the updated shape of the cutting edge meets the discrimination standard.
经过6次模拟后,模拟循环中模具整体受力Fn,max如表6所示,F1,max/Fmax=0.68,符合刃口变形量的判别标准,则判定此时的刃口形状为最适用于该零件的最优模具刃口形状。After 6 simulations, the overall force F n,max of the mold in the simulation cycle is shown in Table 6, F 1,max /F max = 0.68, which meets the criterion for the deformation of the cutting edge, and the shape of the cutting edge at this time is judged is the optimal die edge shape most suitable for the part.
表6Table 6
步骤5,在第6次受塑性变形影响后模具刃口变形的基础上,利用有限元软件及下述磨损模型计算模具刃口的磨损情况:Step 5, on the basis of the deformation of the die edge after the sixth plastic deformation, use the finite element software and the following wear model to calculate the wear of the die edge:
其中,W为磨损量,K为材料的磨损系数,S为模具平均寿命,P为接触应力,v为滑动速度,H为材料的洛氏硬度;模具刃口磨损的计算是基于模具平均寿命与单次精冲磨损相乘的结果,获得了新的刃口形状,如图3所示。Among them, W is the amount of wear, K is the wear coefficient of the material, S is the average life of the mold, P is the contact stress, v is the sliding speed, and H is the Rockwell hardness of the material; the calculation of the wear of the cutting edge of the mold is based on the average life of the mold and The result of multiplication of single fine blanking and wear results in a new cutting edge shape, as shown in Figure 3.
若对于经过前述方法判定后的刃口形状仍不满意,可根据具体工况对最优模具刃口形状进行重新设计,重新设计的最优刃口形状需满足确保零件加工质量、刃口形状与计算结果相似程度高、刃口形状圆滑过渡等要求。对最优模具刃口形状进行重新设计后,可返回步骤1,再次经过本方法进行判定。If you are still unsatisfied with the shape of the cutting edge determined by the above method, you can redesign the optimal mold cutting edge shape according to the specific working conditions. High similarity of calculation results, smooth transition of cutting edge shape and other requirements. After redesigning the optimal mold cutting edge shape, you can return to step 1 and judge through this method again.
以上所述本发明的具体实施方式,并不构成对本发明保护范围的限定。任何根据本发明的技术构思所做出的各种其他相应的改变与变形,均应包含在本发明权利要求的保护范围内。The specific embodiments of the present invention described above do not constitute a limitation to the protection scope of the present invention. Any other corresponding changes and modifications made according to the technical concept of the present invention shall be included in the protection scope of the claims of the present invention.
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