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To optimize drawbead parameters in stamping processes, a simulation model is established by using Autoform, with the resistance coefficient as the evaluation criterion. Orthogonal testing and variance analysis are employed to investigate the influence laws of 9 parameters on drawbead resistance. The results reveal that parameters such as the top fillet radius on the inflow side of the concave drawbead and the height of the convex drawbead significantly influence drawbead resistance, while the wall angle and bottom corner radius have minimal impact. In engireering, regulating the key parameters can reduce defects such as wrinkling and cracking, thereby improving mold debugging efficiency and lowering production costs.

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佟鑫(1988—),男,高级工程师,硕士学位,研究方向为冲压技术。

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佟鑫(1988—),男,高级工程师,硕士学位,研究方向为冲压技术。

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佟鑫(1988—),男,高级工程师,硕士学位,研究方向为冲压技术。

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水平 因素
A
/(°)
B
/(°)
C
/mm
D
/mm
E
/mm
F
/mm
G
/mm
H
/mm
I
/mm
1 0 0 3 3 3 1 3 3 1
2 1 1 4 4 4 2 4 4 2
3 2 2 5 5 5 3 5 5 3
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拉延筋各参数因素水平

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水平 因素
A
/(°)
B
/(°)
C
/mm
D
/mm
E
/mm
F
/mm
G
/mm
H
/mm
I
/mm
1 0 0 3 3 3 1 3 3 1
2 1 1 4 4 4 2 4 4 2
3 2 2 5 5 5 3 5 5 3
), ArticleFig(id=1190298183285707676, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
试验号 试验因素
A/(°) B/(°) C
/mm
D
/mm
E
/mm
F
/mm
G
/mm
H
/mm
I
/mm
1 0 0 3 3 3 1 3 3 1
2 0 0 3 3 4 2 4 4 2
3 0 0 3 3 5 3 5 5 3
4 0 1 4 4 3 1 3 4 2
5 0 1 4 4 4 2 4 5 3
6 0 1 4 4 5 3 5 3 1
7 0 2 5 5 3 1 3 5 3
8 0 2 5 5 4 2 4 3 1
9 0 2 5 5 5 3 5 4 2
10 1 0 4 5 3 2 5 3 2
11 1 0 4 5 4 3 3 4 3
12 1 0 4 5 5 1 4 5 1
13 1 1 5 3 3 2 5 4 3
14 1 1 5 3 4 3 3 5 1
15 1 1 5 3 5 1 4 3 2
16 1 2 3 4 3 2 5 5 1
17 1 2 3 4 4 3 3 3 2
18 1 2 3 4 5 1 4 4 3
19 2 0 5 4 3 3 4 3 3
20 2 0 5 4 4 1 5 4 1
21 2 0 5 4 5 2 3 5 2
22 2 1 3 5 3 3 4 4 1
23 2 1 3 5 4 1 5 5 2
24 2 1 3 5 5 2 3 3 3
25 2 2 4 3 3 3 4 5 2
26 2 2 4 3 4 1 5 3 3
27 2 2 4 3 5 2 3 4 1
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正交试验方案

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试验号 试验因素
A/(°) B/(°) C
/mm
D
/mm
E
/mm
F
/mm
G
/mm
H
/mm
I
/mm
1 0 0 3 3 3 1 3 3 1
2 0 0 3 3 4 2 4 4 2
3 0 0 3 3 5 3 5 5 3
4 0 1 4 4 3 1 3 4 2
5 0 1 4 4 4 2 4 5 3
6 0 1 4 4 5 3 5 3 1
7 0 2 5 5 3 1 3 5 3
8 0 2 5 5 4 2 4 3 1
9 0 2 5 5 5 3 5 4 2
10 1 0 4 5 3 2 5 3 2
11 1 0 4 5 4 3 3 4 3
12 1 0 4 5 5 1 4 5 1
13 1 1 5 3 3 2 5 4 3
14 1 1 5 3 4 3 3 5 1
15 1 1 5 3 5 1 4 3 2
16 1 2 3 4 3 2 5 5 1
17 1 2 3 4 4 3 3 3 2
18 1 2 3 4 5 1 4 4 3
19 2 0 5 4 3 3 4 3 3
20 2 0 5 4 4 1 5 4 1
21 2 0 5 4 5 2 3 5 2
22 2 1 3 5 3 3 4 4 1
23 2 1 3 5 4 1 5 5 2
24 2 1 3 5 5 2 3 3 3
25 2 2 4 3 3 3 4 5 2
26 2 2 4 3 4 1 5 3 3
27 2 2 4 3 5 2 3 4 1
), ArticleFig(id=1190298183457674142, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
n Yn n Yn
1 0.689 15 0.703
2 0.606 16 0.538
3 0.538 17 0.624
4 0.686 18 0.536
5 0.563 19 0.706
6 0.583 20 0.575
7 0.684 21 0.641
8 0.647 22 0.590
9 0.537 23 0.475
10 0.636 24 0.563
11 0.630 25 0.625
12 0.516 26 0.642
13 0.637 27 0.691
14 0.707
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试验结果

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n Yn n Yn
1 0.689 15 0.703
2 0.606 16 0.538
3 0.538 17 0.624
4 0.686 18 0.536
5 0.563 19 0.706
6 0.583 20 0.575
7 0.684 21 0.641
8 0.647 22 0.590
9 0.537 23 0.475
10 0.636 24 0.563
11 0.630 25 0.625
12 0.516 26 0.642
13 0.637 27 0.691
14 0.707
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因素 ${K}_{{i}_{1}}$ ${K}_{{i}_{2}}$ ${K}_{{i}_{3}}$
A 5.533 5.527 5.508
B 5.537 5.507 5.524
C 5.159 5.572 5.837
D 5.838 5.452 5.278
E 5.791 5.469 5.308
F 5.506 5.522 5.540
G 5.915 5.492 5.161
H 5.793 5.488 5.287
I 5.536 5.533 5.499
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因素水平效应和${K}_{{i}_{j}}$

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因素 ${K}_{{i}_{1}}$ ${K}_{{i}_{2}}$ ${K}_{{i}_{3}}$
A 5.533 5.527 5.508
B 5.537 5.507 5.524
C 5.159 5.572 5.837
D 5.838 5.452 5.278
E 5.791 5.469 5.308
F 5.506 5.522 5.540
G 5.915 5.492 5.161
H 5.793 5.488 5.287
I 5.536 5.533 5.499
), ArticleFig(id=1190298183738692514, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 ${K}_{{i}_{1}}^{2}$ ${K}_{{i}_{2}}^{2}$ ${K}_{{i}_{3}}^{2}$
A 30.614 09 30.547 73 30.338 06
B 30.658 37 30.327 05 30.514 58
C 26.615 28 31.047 18 34.070 57
D 34.082 24 29.724 30 27.857 28
E 33.535 68 29.909 96 28.174 86
F 30.316 04 30.492 48 30.691 60
G 34.987 23 30.162 06 26.635 92
H 33.558 85 30.118 14 27.952 37
I 30.647 30 30.614 09 30.239 00
), ArticleFig(id=1190298183818384291, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表5, caption=

不同因素对应的${K}_{{i}_{j}}^{2}$

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 ${K}_{{i}_{1}}^{2}$ ${K}_{{i}_{2}}^{2}$ ${K}_{{i}_{3}}^{2}$
A 30.614 09 30.547 73 30.338 06
B 30.658 37 30.327 05 30.514 58
C 26.615 28 31.047 18 34.070 57
D 34.082 24 29.724 30 27.857 28
E 33.535 68 29.909 96 28.174 86
F 30.316 04 30.492 48 30.691 60
G 34.987 23 30.162 06 26.635 92
H 33.558 85 30.118 14 27.952 37
I 30.647 30 30.614 09 30.239 00
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因素 ${K}_{{i}_{1},av}$ ${K}_{{i}_{2},av}^{2}$ ${K}_{{i}_{3},av}$
A 0.614 78 0.614 11 0.612 00
B 0.615 22 0.611 89 0.613.78
C 0.573 22 0.619 11 0.648 56
D 0.648 67 0.605 78 0.586 44
E 0.643 44 0.607 67 0.589 78
F 0.611 78 0.613 56 0.615 56
G 0.657 22 0.610 22 0.573 44
H 0.643 67 0.609 78 0.587 44
I 0.615 11 0.614 78 0.611 00
), ArticleFig(id=1190298183956796325, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表6, caption=

不同因素对应的${K}_{{i}_{j}},{ }_{av}$

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因素 ${K}_{{i}_{1},av}$ ${K}_{{i}_{2},av}^{2}$ ${K}_{{i}_{3},av}$
A 0.614 78 0.614 11 0.612 00
B 0.615 22 0.611 89 0.613.78
C 0.573 22 0.619 11 0.648 56
D 0.648 67 0.605 78 0.586 44
E 0.643 44 0.607 67 0.589 78
F 0.611 78 0.613 56 0.615 56
G 0.657 22 0.610 22 0.573 44
H 0.643 67 0.609 78 0.587 44
I 0.615 11 0.614 78 0.611 00
), ArticleFig(id=1190298184023905190, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
Qi 10.166 65 10.166 67 10.192 56 10.184 87 10.180 06
因素 F G H I
Qi 10.166 68 10.198 36 10.181 04 10.166 71
), ArticleFig(id=1190298184111985575, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表7, caption=

不同因素对应的Qi

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
Qi 10.166 65 10.166 67 10.192 56 10.184 87 10.180 06
因素 F G H I
Qi 10.166 68 10.198 36 10.181 04 10.166 71
), ArticleFig(id=1190298184187483048, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
SSi 0.000 04 0.000 05 0.025 94 0.018 25 0.013 44
因素 F G H I
SSi 0.000 06 0.031 74 0.014 42 0.000 09
), ArticleFig(id=1190298184267174825, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表8, caption=

不同因素对应的SSi

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
SSi 0.000 04 0.000 05 0.025 94 0.018 25 0.013 44
因素 F G H I
SSi 0.000 06 0.031 74 0.014 42 0.000 09
), ArticleFig(id=1190298184346866602, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
MSi 0.000 02 0.000 03 0.012 97 0.009 13 0.006 72
因素 F G H I
MSi 0.000 03 0.015 84 0.007 21 0.000 05
), ArticleFig(id=1190298184422364075, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表9, caption=

不同因素对应的MSi

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
MSi 0.000 02 0.000 03 0.012 97 0.009 13 0.006 72
因素 F G H I
MSi 0.000 03 0.015 84 0.007 21 0.000 05
), ArticleFig(id=1190298184489472940, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
Fi 0.307 0.408 210.7 148.2 109.1
因素 F G H I
Fi 0.522 257.7 117.1 0.762
), ArticleFig(id=1190298184564970413, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表10, caption=

不同因素对应的Fi

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 A B C D E
Fi 0.307 0.408 210.7 148.2 109.1
因素 F G H I
Fi 0.522 257.7 117.1 0.762
), ArticleFig(id=1190298184636273582, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
因素 SSi dfFA MSi Fi 显著性
A 0.000 04 2 0.000 02 0.307 -
B 0.000 05 2 0.000 03 0.408 -
C 0.026 00 2 0.013 00 210.7 **
D 0.018 00 2 0.009 00 148.2 **
E 0.013 00 2 0.007 00 109.1 **
F 0.000 06 2 0.000 03 0.522 -
G 0.031 00 2 0.016 00 257.7 **
H 0.014 00 2 0.007 00 117.1 **
I 0.000 09 2 0.000 05 0.762 -
), ArticleFig(id=1190298184711771055, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1190284220594487789, language=CN, label=表11, caption=

方差分析

, figureFileSmall=null, figureFileBig=null, tableContent=
因素 SSi dfFA MSi Fi 显著性
A 0.000 04 2 0.000 02 0.307 -
B 0.000 05 2 0.000 03 0.408 -
C 0.026 00 2 0.013 00 210.7 **
D 0.018 00 2 0.009 00 148.2 **
E 0.013 00 2 0.007 00 109.1 **
F 0.000 06 2 0.000 03 0.522 -
G 0.031 00 2 0.016 00 257.7 **
H 0.014 00 2 0.007 00 117.1 **
I 0.000 09 2 0.000 05 0.762 -
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基于Autoform的拉延筋参数正交试验分析
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佟鑫
汽车工艺与材料 | 生产现场 2025,(8): 30-35
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汽车工艺与材料 | 生产现场 2025, (8): 30-35
基于Autoform的拉延筋参数正交试验分析
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佟鑫
作者信息
  • 中国第一汽车股份有限公司, 长春 130011
  • 佟鑫(1988—),男,高级工程师,硕士学位,研究方向为冲压技术。

Orthogonal Experimental Analysis of Drawbead Parameters Based on Autoform
Xin Tong
Affiliations
  • China FAW Co., Ltd., Changchun 130011
出版时间: 2025-08-20 doi: 10.19710/J.cnki.1003-8817.20250054
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为优化冲压拉延中拉延筋参数,基于Autoform建立仿真模型,以阻力系数为评价指标,采用正交试验与方差分析,探究9项参数对拉延阻力的影响规律。结果表明:凹筋流入侧顶端圆角半径、凸筋高度等参数对拉延阻力的影响显著,而立壁角度、底端圆角半径的影响微弱。工程中调控关键参数可抑制起皱、破裂缺陷,提升模具调试效率,降低生产成本。
Autoform  /  拉延筋参数  /  正交试验  /  阻力系数  /  凹筋流入侧顶端圆角半径

To optimize drawbead parameters in stamping processes, a simulation model is established by using Autoform, with the resistance coefficient as the evaluation criterion. Orthogonal testing and variance analysis are employed to investigate the influence laws of 9 parameters on drawbead resistance. The results reveal that parameters such as the top fillet radius on the inflow side of the concave drawbead and the height of the convex drawbead significantly influence drawbead resistance, while the wall angle and bottom corner radius have minimal impact. In engireering, regulating the key parameters can reduce defects such as wrinkling and cracking, thereby improving mold debugging efficiency and lowering production costs.

Autoform  /  Drawbead parameters  /  Orthogonal experimental  /  Resistance coefficient  /  Top Fillet Radius on the Inflow Side of the Concave Drawbead
佟鑫. 基于Autoform的拉延筋参数正交试验分析. 汽车工艺与材料, 2025 , (8) : 30 -35 . DOI: 10.19710/J.cnki.1003-8817.20250054
Xin Tong. Orthogonal Experimental Analysis of Drawbead Parameters Based on Autoform[J]. Automobile Technology & Material, 2025 , (8) : 30 -35 . DOI: 10.19710/J.cnki.1003-8817.20250054
在冲压拉延过程中,板料同时承受模具的作用力、材料自身的变形抗力以及压料面摩擦阻力。在压料力作用下,板料与凹模和压边圈之间的摩擦力往往难以充分满足拉延阻力的要求,因此,需设置拉延筋,构建局部强化阻力带,强化对材料流动的约束[1]
与此同时,板料的流动状态复杂且不均匀,易引起开裂、起皱以及回弹等缺陷。在拉延工艺设计环节,通常会在压边圈和凹模表面设置拉延筋,以控制板料的流动状态[2]。拉延筋的效果显著,可通过调整其高度、圆角半径等参数改变拉延筋对板料流动所施加的阻力,例如,在外覆盖件拉延时,需对板料的流入量予以精准控制,以确保拉延过程充分,减少回弹现象。而对于内板件,则需保证板料均匀流入,防止出现开裂起皱[3]
在科研实践与工程设计中,多因素多水平试验常面临试验组合数量激增的难题。以典型的5因素4水平研究为例,若采用全因子试验设计,需执行1 024(4⁵)组试验,导致时间成本与资源消耗大幅增加,还可能因个别异常试验数据影响整体研究结论的可靠性。为此,需在保证试验数据有效性的前提下优化试验规模。
正交试验法基于伽罗瓦域(Galois Field)数学理论构建正交性试验设计框架,通过正交表筛选具有空间均衡分布特性的代表性样本组合。以5因素4水平正交表L16(4⁵)为例,进行试验设计时,仅开展16组试验即可覆盖全因子空间92.3%的信息量(根据田口损失函数(Taguchi Loss Function)计算)[4]。该方法通过标准化正交矩阵的构建,实现了试验次数的对数级缩减与结果有效性的平衡,具备高效性、普适性及经济性等显著工程优势。
在试验设计与数据分析中,需明确以下3个核心参数:
a. 结果指标是表征试验目标达成程度的可测量化参数,需满足测量可行性、敏感性及与研究目标的一致性要求。例如,在材料成型领域可选取拉延件的壁厚减薄率、回弹量作为指标,在农业研究中常以作物亩产量、蛋白质含量作为评价依据。其作用是为试验效果提供客观量化的判断标准。
b. 影响因素指对结果指标产生显著作用的独立变量集合,标记为ABC等。以汽车覆盖件拉延工艺为例,拉延筋高度A、圆角半径B、压料力C等均可作为关键影响因素。正交试验法的核心价值在于,通过统计分析解析多因素主效应及交互作用的显著性排序,为复杂系统优化提供科学依据。
c. 水平是各影响因素在试验中设定的具体参数取值,需满足正交表“均衡分散、整齐可比”的设计原则。水平取值可为等间距(如温度因素设为30 ℃、40 ℃、50 ℃)、等比或其他合理区间,通常按顺序编码为1、2、3[5]以便于正交表的标准化处理。合理的水平设置是保证试验数据具有统计规律性的基础。
在汽车覆盖件拉延工艺仿真中,基于Autoform软件平台,拉延筋的几何参数对板料流动阻力具有显著影响,其相关参数如图1所示,本研究选取流入侧立壁角度、流出侧立壁角度、凸筋高度、凸筋流入侧顶端圆角半径、凸筋流出侧顶端圆角半径、凸筋底端圆角半径、凹筋流入侧顶端圆角半径、凹筋流出侧顶端圆角半径、凹筋底端圆角半径共9项关键参数作为试验因素,各因素均设置3个水平。
同时,为构建标准化试验体系,将上述因素依次定义为A:流入侧立壁角度,其3个水平依次记为A1(0°)、A2(1°)、A3(2°);B:流出侧立壁角度,水平设置同因素AC:凸筋高度,3个水平依次为C1(3 mm)、C2(4 mm)、C3(5 mm);D:凸筋流入侧顶端圆角半径,水平设置同因素CE:凸筋流出侧顶端圆角半径,水平设置同因素CF:凸筋底端圆角半径,3个水平为F1(1 mm)、F2(2 mm)、F3(3 mm);G:凹筋流入侧顶端圆角半径,水平设置同因素CH:凹筋流出侧顶端圆角半径,水平设置同因素CI:凹筋底端圆角半径,水平设置同因素F。各因素的具体水平取值严格遵循拉延筋几何设计规范及数值模拟收敛性要求,如表1所示。
由于标准正交试验表中不存在9因素3水平的表格,研究采用Mintab软件生成专用正交试验表L27(39),该设计方案仅需进行27次试验。相较于全因子试验所需的19 683(39)次试验,试验效率提升729倍,有效平衡了计算成本与数据有效性。
表1中各个因素的各水平值分别带入正交试验表中,形成包含27组工况的试验方案,如表2所示。
本研究选取拉延筋阻力系数作为试验结果指标,按照表2所示的27组正交试验方案开展模拟试验,测得的阻力系数结果如表3所示。为便于数据处理与分析,将试验结果记为Ynn=1,2,…, 27),如第1组试验结果记为Y1=0.689。
${K}_{{i}_{j}}$为某i因素第j水平所对应的全部试验结果总和,i的取值范围为{A,B,C,…,I},j的取值范围为{1,2,3},反映该水平对试验指标的总体影响。以因素A(流入侧立壁角度)第1水平(A1)为例,其对应试验号为1~9(A因素第1水平的所有组合),计算得:
${K}_{{A}_{1}}$=Y1+Y2+Y3+Y4+Y5+Y6+Y7+Y8+Y9
表3数值带入式(1)中得到${K}_{{A}_{1}}$=5.533。
因素E(凸筋流出侧顶端圆角半径)第2水平(E2)对应试验号为2、5、8、11、14、17、20、23、26,其效应和${K}_{{E}_{2}}$为:
${K}_{{E}_{2}}$=Y2+Y5+Y8+Y11+Y14+Y17+Y20+Y23+Y26
表3数值带入式(2)中得到${K}_{{E}_{2}}$=5.469。
因素I(凹筋底端圆角半径)第3水平${K}_{{I}_{3}}$为:
${K}_{{I}_{3}}$=Y3+Y5+Y7+Y11+Y13+Y18+Y19+Y24+Y26
表3数值带入式(3)中得到${K}_{{I}_{3}}$=5.499。
按上述方法计算所有因素各水平的${K}_{{i}_{j}}$值,结果如表4所示。
${K}_{{i}_{j}}^{2}$为各因素水平效应和的平方,用于后续方差分析中的离差计算,即${K}_{{i}_{j}}$值的平方值。以${K}_{{A}_{1}}$=5.533、${K}_{{E}_{2}}$=5.469、${K}_{{I}_{3}}$=5.499为例计算:
${K}_{{A}_{1}}^{2}={\left({K}_{{A}_{1}}\right)}^{2}$
${K}_{{E}_{2}}^{2}={\left({K}_{{E}_{2}}\right)}^{2}$
${K}_{{I}_{3}}^{2}={\left({K}_{{I}_{3}}\right)}^{2}$
表4数据代入式(4)~式(6)计算得出,${K}_{{A}_{1}}^{2}$=30.614 09,${K}_{{E}_{2}}^{2}$=29.909 96,${K}_{{I}_{3}}^{2}$=30.239 00。同理获得其他各因各水平的${K}_{{i}_{j}}^{2}$值,如表5所示。
${K}_{{i}_{j},av}={K}_{{i}_{j}}$/9(每组水平包含9次试验)为各i因素第j水平的试验结果平均值,反映该水平对阻力系数的平均影响,以 ${K}_{{A}_{1},av}$${K}_{{E}_{2},av}$${K}_{{I}_{3},av}$为例计算如下:
${K}_{{A}_{1},av}$=${K}_{{A}_{1}}$/9
${K}_{{E}_{2},av}$=${K}_{{E}_{2}}$/9
${K}_{{I}_{3},av}$=${K}_{{I}_{3}}$/9
表4数据代入式(7)~(9)计算得,${K}_{{A}_{1},av}$=0.614 78、${K}_{{E}_{2},av}$=0.607 67、${K}_{{I}_{3},av}$=0.611 00。
各元素各水平的${K}_{{i}_{j},av}$值如表6所示。
正交试验数据分析的核心是通过方差分析(ANOVA)量化各因素对拉延筋阻力系数的影响,依据不同水平下指标波动幅度识别关键因素与次要因素。方差分析通过分解总偏差平方和为因素效应平方和与误差平方和,构造F统计量进行显著性检验,具体分析步骤如下。
试验的总次数n=27,因素的水平数m=3,单水平重复试验次数r=n/m,经计算,r=9。
指标总和为:
$T=\sum _{n=1}^{27}{Y}_{n}$
指标的平方之和为:
${Q}_{T}=\sum _{n=1}^{27}{Y}_{n}^{2}$
经计算,T=16.568,QT=10.278 19。
校正项为:
CT=T 2/n
总偏差平方和为:
SS=QT-CT
总自由度为:
dfTO=n-1
单因素自由度为:
dfFA=m-1
经计算,CT=10.166 62,SS=0.111 57,dfTO=26,dfFA=2。
因素A的效应平方和为:
${Q}_{A}=({K}_{{A}_{1}}^{2}+{K}_{{A}_{2}}^{2}+{K}_{{A}_{3}}^{2})/r$
经计算,QA=10.166 65。
同理计算获得其他各因素的Qi值,如表7所示。
因素A的偏差平方为:
SSA=QA-CT
经计算,SSA=0. 000 04。
同理,计算获得其他各因素的SSi值,如表8所示。
因素A的方差为:
MSA=SSA/dfFA
经计算,MSA=0. 000 02。
同理,计算获得其他各因素的MSi值,如表9所示。
由上述结果分析可知,取对结果影响较小的ABFI因素方差的均值作为误差方差MSER
MSER=(MSA+MSB+MSF+MSI)/4
因素AF统计量为:
FA=MSA/MSER
经计算,FA=0.307。
同理,计算获得其他各元素的Fi值,如表10所示。
误差自由度dfER为:
dfER=dfTO-dfFA×r
经计算,dfER=8。
选取0.01、0.05为判断标准,查询F分布表得F0.05(2,8)=4.46、F0.01(2,8)=8.65。
Fi<4.46时,该因素对试验结果无显著影响;当4.46<Fi<8.65时,该因素对试验结果有一定影响;当Fi>8.65时,该因素对试验结果有显著的影响。
根据表10中的Fi统计量值完成显著性检验,获得方差分析表,如表11所示。
表11可知,各因素对试验指标影响的显著顺序为因素G(凹筋流入侧顶端圆角半径)>因素C(凸筋高度)>因素D(凸筋流入侧顶端圆角半径)>因素H(凹筋流出侧顶端圆角半径)>因素E(凸筋流出侧顶端圆角半径)>因素I(凹筋底端圆角半径)>因素F(凸筋底端圆角半径)>因素B(流出侧立壁角度)>因素A(流入侧立壁角度)。
某车型前门窗框加强板在批量生产中,窗框上侧开裂缺陷频发,如图2所示。经分析,原工艺中凹筋流入侧顶端圆角半径为4 mm,对应因素G的水平2。缩小圆角半径会显著增大材料流动阻力,导致局部应力集中,如图3所示,绿色面为凹筋流入侧顶端圆角。根据本文研究结果进行整改,将凹筋流入侧顶端圆角半径增大至4.5 mm,降低板料流动阻力。整改后,批量生产1 200件,原开裂区域未出现缺陷,零件尺寸稳定性达标。
某车型后门内板在批量生产中,零件上侧频繁出现开裂现象,如图4所示。原工艺凹筋流入侧顶端圆角半径为3.7 mm,理论分析表明,较小的圆角半径会加剧材料流入阻力不均,引发局部拉裂。根据本研究进行整改,把凹筋流入侧顶端圆角半径由3.7 mm增大至4.2 mm。整改后,批量生产800件,开裂缺陷完全消除。
本文基于Autoform软件平台建立拉延筋仿真模型,以阻力系数为评价指标,即结果数值越高,说明拉延筋的阻力越大,通过正交试验法与方差分析,系统研究了拉延筋9项几何参数对阻力特性的影响。结果表明,凹筋流入侧顶端圆角半径对拉延筋的阻力影响最大,其次为凸筋高度、凸筋流入侧顶端圆角半径、凹筋流出侧顶端圆角半径、凸筋流出侧顶端圆角半径,而流入侧立壁角度、流出侧立壁角度、凸筋底端圆角半径、凹筋底端圆角半径对阻力特性的影响可忽略不计。
上述结论为冲压工艺优化提供了量化依据:可通过调控关键参数(如放大凹筋流入侧顶端圆角半径、优化凸筋高度)精准控制板料流动阻力的。此方法不仅能有效抑制拉延过程中起皱、破裂等缺陷,还可显著提升模具调试效率,通过减少工艺方案迭代次数、缩短验证周期降低模具修正成本。
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韩利芬, 李光耀, 钟志华, 等. 板料成形中等效拉延筋阻力的模拟计算方法[J]. 汽车工程, 2006(11): 1015-1019.
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doi: 10.19710/J.cnki.1003-8817.20250054
  • 首发时间:2025-10-29
  • 出版时间:2025-08-20
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    中国第一汽车股份有限公司, 长春 130011
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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