全文总字数：41617字

1. 研究目的与意义（文献综述）

1.purpose and significance (including analysis of research status in china and abroad)

2. 研究的基本内容与方案

2.Research (design) basic content, goals, proposed technical solutions and measures

2.1 Basic research content

(1) Structural analysis of rear exhaust pipe of stainless steel

According to the information provided by the enterprise, the common materials of the stainless steel rear exhaust tail pipe of the car are analyzed, and the geometric structure and actual production need to meet the requirements of dimensional accuracy and forming quality.

(2) Finite element modeling of stamping forming of stainless steel rear exhaust tailpipe of car

Establish 3D model, import dynaform, complete grid division and control of grid parameters, establish supplementary surface, determine material type, perform parameters, estimate billet size and finish other numerical simulation pre-processing processes.

(3) Analysis of stamping forming and process of stainless steel rear exhaust tail pipe of car

The model is used for simulation analysis. The influence of key process parameters such as blank holder force, friction coefficient, die and die clearance, and stamping speed on the dimensional accuracy and forming quality of the exhaust tail pipe of the car is analyzed, and the exhaust tail of the car is also analyzed. Regarding the requirements and functions of each stamping process, analyze whether there are places that can be optimized.

(4) Testing and control of stamping precision of stainless steel rear exhaust tail pipe

According to the analysis results and the detection of the accuracy after forming, determine the impact of key process parameters on the dimensional accuracy and forming quality of the car exhaust tail pipe stamping process and the requirements and functions of each stamping process. Based on this, optimize the design and obtain the car exhaust. The best process parameters and the best stamping scheme in the tail pipe stamping process were verified.

2.2 Research objectives

Combined with the actual production of the enterprise, a three-dimensional model of the exhaust tail pipe of the car is established, and the complicated working conditions of the stainless steel exhaust tail pipe stamping of the car are difficult to control. The dimensional accuracy and forming quality control are studied to develop The precision sheet metal forming technology is then used to simulate and optimize the entire stamping process and verify the rationality of the analysis and design, so as to provide a certain reference for optimizing the process of stamping the exhaust tail pipe of the car.

2.3 Technical route

(1) Based on the dimensional parameters given in the drawings, complete the design of the overall structure of the car exhaust tailpipe and the design of key components;

(2) Establish a three-dimensional model of the exhaust tail pipe of the car and import it into Dynaform;

(3) Simulation of the stamping process of the exhaust tail pipe of the car;

(4) Analyze the influence of each process parameter and optimize the simulation results;

(5) Determine the final stamping process route after the optimization is completed；

(6) Simulation verification of control springback accuracy

Overall structure design andkey parts design of car exhaust tail pipe

Building a 3D model of a car exhaust tailpipe

Simulation of stamping processof car exhaust tail pipe

Process parameter analysis,simulation result analysis

Optimization of stamping process route

Perform precision control simulation verification

3. 研究计划与安排

3. Schedule

4. 参考文献（12篇以上）

4. References

[1]Xiaohui Cui, Zhiwu Zhang, Zhihao Du, Hailiang Yu, Dongyang Qiu, Yongqi Cheng, Xiaoting Xiao. Inverse bending and springback-control using magnetic pulse forming[J], Journal of Materials Processing Tech, 2020,275:1-13.

[2]C.Han, H.Feng, S.J.Yuan. Springback and compensation of bending for hydroforming of advanced high-strength steel welded tubes[J], The International Journal of Advanced Manufacturing Technology, 2017,89:9-12.

[3]Jun Fang, Shiqiang Lu, Kelu Wang, Zhengjun Yao. Springback law of high-strength 21-6-9 stainless steel tube in numerical control bending under different process parameters[J], Proceedings of the Institution of Mechanical Engineers, 2017,231(10):1-10.

[4]Zhiying Sun, Lihui Lang. Study on hydroforming process and springback control of large sheet with weak rigidity[J], International Journal of Precision Engineering and Manufacturing, 2017,18(6):903-912.

[5]F.Z.Oujebbour, A.Habbal, R.Ellaia. Optimization of stamping process parameters to predict and reduce springback and failure criterion[J], Structural and Multidisciplinary Optimization, 2015,51(2): 495-514.

[6]C.J.Su, X.H.Dong, Q.Wang, Y.D.Mu. Study on the effects of forming parameters on the plastic flow of axisymmetrical curved parts in stamping process[J], Materials Research Innovations, 2015,19:1-7.

冲压成形过程中成形参数对轴对称曲面零件塑性流动的影响研究

[7]尚琪,乔顺成,吴建军,张增坤,杨俊宙,邬洪飞,任银香.管件弯曲过渡区研究及回弹控制[J]，塑性工程学报，2020,27(01):38-45.

[8]高辉，刘波，李小曼，肖家源，龚强，王本安.5A06铝合金T型变管径半管冷冲压成形工艺[J]，锻压技术，2019,44(03):36-40.

[9]谢晖,唐长民,程威,张文彦,王东福.多弯角零件冲压回弹控制方法的研究[J]，塑性工程学报，2018,25(01):22-27.

[10]唐长民.多弯角车身件冲压回弹控制与同步工程技术研究[D]，湖南大学，2017.

[11]肖红波，蔡浩华.轿车侧围外板冲压成形工艺优化[J]，模具工业，2017,43(08):28-30.

[12]童琳.弧形板冲压成形及其精度控制研究[D]，哈尔滨工业大学，2016.

[13]刘海静.汽车顶盖冲压成形数值模拟及回弹优化研究[D]，长春工业大学，2016.

[14]杨忠炯,袁宏亮,周立强,姜东身.复杂空间曲面薄板冲压成形回弹预测[J]，长安大学学报(自然科学版)，2016,36(04):119-126.

[15]李健.镀镍薄板冲压成形过程中的回弹研究及稳健设计[D]，湘潭大学，2016.

[16]周文浩. 板料弯曲回弹控制及数值模拟精度研究[D]，哈尔滨理工大学，2015.

[17]薛冰冰,刘和平,何聪.薄壁箱形金属管材冲压成形试验研究[J]，机床与液压，2015,43(07):32-34.

[18]赵艳龙,齐晓冬.高精度薄板冲压模具的设计与加工[J]，模具制造，2014,14(08):16-18.

[19]高伟.轿车非典型U形件冲压成形工艺和模拟研究[D]，吉林大学，2013.

[20]徐虹，马东，谷诤巍，李欣.侧立柱冲压成形截面开口尺寸精度控制方法研究[J]，模具工业，2013,39(10):34-37.

文献检索摘要

1.黎镇浩.基于电磁力驱动的筒形件冲压成形的数值模拟和实验研究[D]，华中科技大学，2019.

针对现有诸多成形技术在轻质深冲型筒形件成形应用中的不足，本文提出了基于电磁力驱动的新型筒形件冲压成形技术。在成形模型建立方面，开展了大/复杂变形下电磁-结构场耦合模型研究，提出并构建了基于改进电流丝法的场路耦合数值模型，实现了基于电磁力驱动的筒形件冲压成形的精确计算；在成形方法实现方面，针对现有电磁成形技术存在的工件形状精确控制难等不足，提出了基于电磁力驱动的筒形件冲压成形技术，在阐明成形原理的基础上对成形系统进行了参数设计并搭建了实验平台；在成形行为研究方面，基于数值模型和实验平台开展了工件在不同放电参数下的成形特性研究，阐明了电流波数、振荡频率和振荡模式对工件变形量的影响规律及揭示了相关影响机制，在此基础上初步探究了大拉深比筒形件成形的可行性。

2.高辉，刘波，李小曼，肖家源，龚强，王本安.5A06铝合金T型变管径半管冷冲压成形工艺[J]，锻压技术，2019,44(03):36-40.

5A06铝合金是Al-Mg防锈铝合金的一种，具有强度高、耐腐蚀性好、焊接性能良好等一系列特点，以5A06铝合金为原材料的T型半管是航空、航天及汽车等管路结构件中一种常见的结构。由于5A06铝合金室温下塑性成形能力差，在一定程度上制约着该合金的进一步应用。

在T型半管成形过程中影响板料冲压成形质量的主要缺陷为拉裂和褶皱。以上两种缺陷均会对板料的成形质量造成极大的影响，是冲压成形工艺中应当避免的缺陷。本文结合有限元模拟和实验验证，分析研究了T型变管径半管冷冲压成形时凹模圆角和毛料尺寸对零件成形的影响，为冲压模具设计提供参考依据，同时为5A06铝合金半管零件的冷冲压成形提供工艺支持。

3.Beomjoon Choi, Junghwan Choi, Soojeong Heo, Seungwon Shin. Parametric investigation of the effect from controlling variables on thermal deformation during stamping process in automotive body part [J], Applied Thermal Engineering, 2018,140:373-385.

The purpose of this study is to analyze the thermal deformations that degrade the quality of assembled products through the stamping process. Special attention was paid to the ambient temperature change in the manufacturing process of automotive body part. First, we found that ambient temperature, which is the external condition and difficult to control, can be varied significantly due to seasonal change thus it can be an important factor for the deviation from thermal deformation. Important controlling factors for thermal deformation were identified and their effects on final dimensional changes were carefully analyzed by the design of experiments (DOE) procedure. Based on DOE result, we found that the influence of each controlling factor was non-uniform across the target surface. To understand the local variation clearly, vectorized plot of the thermal deformation was introduced for visualization. Locations vulnerable to thermal deformation have been identified and it was confirmed that ambient temperature change has significant effect especially on those weak spots. Finally, we tried to reduce the deviation from thermal deformation by controlling the initial temperature of the mold and the blank. We found that controlling the initial blank temperature was more effective.

本文研究的目的是通过研究冲压过程来分析如何降低影响产品质量的热变形。在汽车车身零件的制造过程中，特别要注意的是环境温度的变化。首先，本文发现环境温度是外部条件，难以控制，它会随季节交替而发生显著变化，因此它可能是热变形发生偏离的一个重要因素。确定了热变形的重要控制因素后，本文通过实验程序的设计（DOE）仔细分析了它们对最终尺寸变化的影响。根据DOE的结果，发现每个控制因素对物体表面的影响是不均匀的。为了清楚地了解局部变化，引入了热变形矢量可视化图。在确定了容易发生热变形的位置后，本文证实了环境温度的变化对热变形具有显著影响，特别是对那些脆弱的点来说。最后，本文试图通过控制模具和坯料的初始温度来减少热变形引起的尺寸偏差，最终发现控制坯料初始温度更为有效。

4.肖红波，蔡浩华.轿车侧围外板冲压成形工艺优化[J]，模具工业，2017,43(08):28-30.

侧围外板是轿车车身外形最大、最复杂的覆盖件，其特点是外形尺寸大、结构复杂、外表面质量和装配精度要求高，这些要求都在冲压工艺中体现和实施。传统的轿车侧围外板冲压工序一般都超过5道，为提高生产效率，降低生产成本，本文会在保证制件成形质量的前提下对各工艺进行科学有效的复合，实现减少工序的目的。

通过采用特殊的复合结构模具，使轿车侧围外板冲压工艺中的修边与整形复合、直翻边整形与斜楔翻边复合及直翻边与斜楔冲孔复合，本文实现了冲压工序数量由5道减少至4道。这降低了生产成本，对同类制件的冲压成形具有很好的借鉴作用。

5.鲍月峰.汽车前翼子板冲压成形的实验及数值仿真研究[D]，吉林大学，2017.

本文以某车型前翼子板为研究对象，对前翼子板的冲压工艺进行了分析，设置初始工艺参数，建立了前翼子板冲压成形有限元模型，对冲压成形过程进行了仿真和优化，获得了最优参数组。利用设置最优参数组的冲压成形工艺在生产线进行试验，再利用检具、三坐标、整车匹配对实际生产的前翼子板进行质量检验，检验结果表明满足各项标准要求并应用于批量生产。

最终，研究结果表明：将冲压工艺设计方案首先进行模拟并优化，不仅可以获得关键工艺参数的最优参数组，而且还可以缩短开发周期，减少开发费用，提高覆盖件质量。

6.Huajun Yan, Qiqi Zang, Shibo Ma, Shuangjie Zhang and Yuzhong Liu. Research on Stamping Process Design and Forming Law of Floor Beam[C], Science and Engineering Research Center, 2017:208-213.

Aiming at the problems of cracking and wrinkling in the forming process of floor beam, the design of the drawing die is finished, and the finite element analysis software DYNAFORM is used to analyze the drawing process of the floor beam, and the effects of blank holder force and drawbead on the formed part are analyzed. The finite element software was used to design the drawing die of the floor beam, and the rule of metal flow in the forming process was analyzed. The effects of drawbead and blank holder force on the forming quality of the part are analyzed. With the maximum thinning rate and maximum thickening rate as the evaluation index, the optimized process parameters are that blank holder force is F = 270kN and drawbead is set to segmented drawbead. The results have important reference value for the forming application of floor beam.

针对楼梁冲压成型过程中出现的开裂，起皱等问题，本文需要完成拉模设计，并利用有限元软件DYNAFORM去分析楼梁的拉伸过程。尤其需要着重分析料坯支架受力及成型过程中拉延筋的影响。利用有限元软件对楼梁的拉模进行设计，本文分析了成形过程中的金属的流动规律并分析了拉延筋和压边力对零件成形质量的影响。以最大减薄率和最大增粗率为评价指标，本文优化后的工艺参数为料坯支架力F=270kN，同时将拉延过程设置为分段拉延。经验证，本文的结果对楼梁的成形应用具有重要的参考价值。

7.王勇胜.热冲压成形工艺的发展及相关模具材料的研究进展[J]，模具制造，2017,17(09):1-5.

上世纪中叶，瑞典SSAB首先开发出热冲压钢板；20世纪70年代开始，热冲压工艺及在乘用车上的研究开始进行；1984年SSAB成为率先使用热冲压零件的汽车厂；20世纪90年代，阿赛洛钢厂开展了热冲压技术研究，攻克了相关核心技术，开发出全球闻名的镀层热冲压用钢Usibor1500。2008-2010年，国外大约有110条热冲压生产线，主要分布在美国、德国、日本、法国、西班牙、瑞典等国家。其中，欧洲集合了全球著名的热冲压产线、热冲压模具及相关零件的供应商，其热冲压线占到全球的70%以上，是热冲压的热点地区。2009年，中国开发出了国内第一条具有完全自主知识产权的高强钢板热成形生产线^[8]。

目前，全球约有400条热冲压生产线。而随着国内自主品牌热成形零件的增加和合资品牌钢材的国际化，国内热冲压零件企业打破了外贸品牌垄断的热成形零件市场。截至目前为止，国内热成形生产线大约在100条（含在建），主要集中在东北、华北和华东等地区。

8.童琳.弧形板冲压成形及其精度控制研究[D]，哈尔滨工业大学，2016.

弧形板是输弹车上的托弹盘，为了保证弧形板与底座之间的装配精度，减轻炮弹在运输过程中与弧形板之间的碰撞及表皮磨损，要求弧形板应该具有较高的表面质量和尺寸精度。根据弧形板的实际生产加工可知，拉裂和回弹是其主要的成形缺陷。因此，本文通过理论分析、数值模拟、参数优化和试验验证研究了弧形板的弯曲成形规律，进而指导实际生产加工过程。

本文理论分析了弧形板各弯曲成形区的应力应变状态，推导了相应成形区的应力应变解析式，分析了弧形板拉裂和回弹缺陷产生的原因，确定了拉裂缺陷和回弹缺陷的评价标准。本文建立了弧形板冲压成形Dynaform有限元模型，研究了模具间隙、翻边圆角半径、冲压速度、摩擦系数和材料对弧形板冲压成形性能的影响规律。本文进行了弧形板冲压成形试验，对弧形板成形工艺参数进行了优化，确定了整体优化方案，建立了工艺参数优化数学模型，其中包括确定优化目标、选取设计变量以及确定约束条件。

结果表明：08Al材料更适用于冷冲压；根据弧形板的形状尺寸，应该使用模具整体成形；为了控制回弹，最好选择机油作为润滑剂。

9.刘海静.汽车顶盖冲压成形数值模拟及回弹优化研究[D]，长春工业大学，2016.

汽车覆盖件的成形质量直接关系到整车的市场认可程度，回弹作为板料冲压成形过程中影响成形质量的关键因素，已经得到了广大科研工作者的重视，但仍存在许多难以解决的问题。本文以某轿车顶盖为例，对其冲压成形过程及回弹进行数值模拟分析，从而研究了控制成形质量与回弹现象的关键技术。

本文利用DYNAFORM有限元分析软件对汽车顶盖的冲压成形过程进行了数值模拟分析，对比了无拉延筋、均匀分布拉延筋、分段变截面拉延筋三种不同拉延筋布置形式下覆盖件的成形特点，最终选取7段不同截面的拉延筋，得到较好成形质量。本文对汽车顶盖的回弹进行数值模拟计算，分析了影响回弹量的主要因素，并判断出不同因素对回弹的影响强度顺序为压边力>虚拟冲压速度>摩擦系数>模具间隙。最后，本文利用了DYNAFORM的回弹补偿模块对汽车顶盖进行回弹补偿研究。在所得最佳组合参数基础上，采用虚拟试模法对其进行回弹补偿，通过三次迭代最终将板料的回弹量控制在2mm以内，得到满足质量要求的产品，并对其进行实际生产。

10.F.Z.Oujebbour, A.Habbal, R.Ellaia. Optimization of stamping process parameters to predict and reduce springback and failure criterion[J], Structural and Multidisciplinary Optimization, 2015,51(2): 495-514.

Automotive manufacturers have been struggling with the big challenge of how to produce dimensionally acceptable stamped parts with minimal material cost. The thin nature of the sheet metal has always complicated the process and made the dimensional quality objectives difficult to achieve. The final layout quality is impacted by several fabrication flaws such as springback and failure. The aim of this paper is to introduce an efficient methodology to deal with complex, computationally expensive multicriteria optimization problems. Our approach is applied to springback and failure criteria. To optimize these two criteria, a global approach was chosen. It is the Simulated Annealing algorithm hybridized with the Simultaneous Perturbation Stochastic Approximation in order to gain in time and in precision. The multicriteria concern amounts to the capture of the Pareto Front associated to the two criteria. Indeed, springback and failure are two conflicting criteria. Normal Boundary Intersection and Normalized Normal Constrained Method are considered for generating a set of Pareto-optimal solutions with the characteristic of uniform distribution of front points. The computational results are compared to those obtained with the well-known Nondominated Sorting Genetic Algorithm II. The results show that our proposed approach is efficient to deal with the multicriteria parametric and shape optimization of highly non-linear mechanical systems.

如何以最低的材料成本生产尺寸可接受的冲压零件，这是汽车制造商一直在烦恼的巨大问题。生产过程中，采用薄型板料往往会使加工过程复杂化并使得尺寸和质量的目标难以实现。同时，产品最终的质量一般又会受到几个制造缺陷的影响，如回弹和故障。本文会介绍一种有效的方法来处理这些复杂的、计算昂贵的多准则优化问题，并将其应用于回弹和失效准则中来。为了优化这两个准则，本文选择了一种通用的方法。它是通过模拟退火算法和同时扰动随机逼近算法来获得时间和精度的。经过多准则的相互联系来捕获与这两个准则相关联的帕累托阵线。事实上，反弹和失效是两个相反的准则。所以本文使用了正态边界交叉和归一化正态约束法来生成一组具有前点均匀分布特征的帕累托最优解，并将计算结果与著名的非支配排序遗传算法II进行了比较。结果表明，本文提出的方法在处理多准则参数和高度非线性机械系统的形状优化方面是非常有效的。

11.C.J.Su, X.H.Dong, Q.Wang, Y.D.Mu. Study on the effects of forming parameters on the plastic flow of axisymmetrical curved parts in stamping process[J], Materials Research Innovations, 2015,19:1-7.

As the rapid development of society and economy, the traditional research method cannot be adapted to the rapid manufacturing industry. The rapid development of computer technology provided a new means for controlling plastic flow of sheet metal. In recent years, with the continuous development of finite element method, using the finite element software in the moulding process has become a trend.

This study is based on the finite element analysis software to conduct simulation analysis of the stamping process of sheet metal. Through the dynamic simulation of the growth parameters, we identify the best combination of different material parameters in the stamping process. In this paper, using the finite element analysis software the analysis is carried out, and the cylindrical parts are taken as the research object, research on the formability of 08Al sheet, ST12 and H62 in different conditions is conducted. The influence the process conditions have on the forming quality is as follows: The more the friction coefficient, the more conducive to the sheet flow, and was good for sheet forming. While the friction coefficient is too small, it will cause wrinkling. The gap is too large, the springback problem is too serious; if the gap is too small, it will be easy to cause the part crack. The large blank holder force can prevent the flange area wrinkling, but if the BHF is too large, it will cause the material flow which is not sufficient and result in part crack.

随着社会经济的快速发展，传统的研究方法慢慢不能适应快速制造业了。计算机技术的飞速发展为控制板料的塑性流动提供了一种新的手段。近年来，随着有限元方法的不断发展，在成型过程中使用有限元软件已成为一种趋势。

文中，本文基于有限元分析软件对板料冲压过程进行模拟分析，通过对生长参数的动态模拟，确定了冲压过程中不同材料参数的最佳组合。此外，以圆柱形部件为研究对象，本文利用有限元分析软件对08Al片、ST12和H62在不同条件下的成形性进行了研究。最终发现其工艺条件对成形质量的影响如下：摩擦系数越小，越有利于板料的流动，有利于板料的成形，但是摩擦系数太小会引起起皱。间隙过大，回弹问题太严重；间隙过小，又容易造成零件开裂。大的料坯支架力可以防止法兰区域起皱，但如果料坯支架力过大，又会造成材料流动不足，导致部分裂纹。

12.胡蕾.铝合金车门外板冲压成形工艺设计与工艺参数稳健优化[D]，湖南大学，2014.

铝合金材料因密度小、强度高、耐腐蚀等优点受到各大汽车厂商的青睐。由于晶体结构与钢存在显著差异，钢板冲压成形理论直接应用在铝板冲压成形中往往无法获得良好的成形结果，且传统的依靠经验与反复试模、修模的工艺设计方法往往使得产品开发成本高，投放市场周期长，需要探寻适合铝板成形的冲压工艺设计方法，同时提高设计效率。

针对这些问题，本文将有限元方法与稳健优化设计相结合，运用先进的σ质量管理思想，建立了基于响应面的铝板冲压成形工艺参数σ稳健优化方法。同时，本文详细分析了影响铝板冲压成形质量的因素，并运用图、减薄率等量化了板料冲压成形缺陷评价标准，并根据铝合金板料成形特点，基于平台介绍了针对铝板成形的工艺设计和数值模拟方法，对某车型铝合金车门外板进行了冲压成形仿真。最后，本文运用板料冲压成形工艺σ稳健优化方法对铝合金车门外板成形工艺参数进行了优化设计。

13.徐虹，马东，谷诤巍，李欣.侧立柱冲压成形截面开口尺寸精度控制方法研究[J]，模具工业，2013,39(10):34-37.

在冲压件生产过程中，工件成形截面的开口尺寸精度一直是冲压工艺研究的重点内容。为解决某地铁碳钢车辆侧立柱成形截面的开口尺寸精度问题，本文先后采用反弯曲回弹补偿法、凹模底部加圆角和凹模侧壁内倾3种开口尺寸精度控制方法进行成形精度数值模拟，研究了反弯曲弦高N、压边力、顶料力、镦圆角和凹模侧壁内倾角度对成形精度的影响。本文针对各方法对于控制截面开口尺寸精度的局限性，提出了3种方法相结合的精度控制方案，对侧立柱进行了数值模拟分析和试验验证。结果表明，该方案可以有效将截面开口尺寸精度控制在设计误差范围内。

14.高伟.轿车非典型U形件冲压成形工艺和模拟研究[D]，吉林大学，2013.

我们将板料毛坯、棒料、管材和型材弯成具有一定曲率、一定角度和形状的冲压成形工序称之为弯曲。弯曲的过程实质上就是金属板料的弹塑性变形过程。

因此，在弯曲时，除了要考虑到有改变金属形状的塑性变形以外，同时还必须注意伴随有弹性变形的存在。

为了对其进行研究，本文以典型U形冲压件自由弯曲过程为研究对象，利用板料冲压成形模拟软件DYNAFORM对其弯曲成形过程进行数值模拟，主要讨论材料性能、相对圆角半径和模具间隙等因素对U形冲压件自由弯曲后回弹量的影响，为冷轧钢板和铝合金板材的弯曲回弹量提供了数值上的帮助。此外，本文利用模拟软件DYNAORM对某轿车上非典型U形冲压件的冲压成形工艺进行了模拟，主要研究了凸、凹模间隙、凸模速度，摩擦系数等因素对成形效果的影响，发现本文研究的非典型U形件在过大或过小的摩擦系数下成形都会导致破裂现象的发生。

15.Katsuyoshi Ikeuchi, Jun Yanagimoto. Valuation method for effects of hot stamping process parameters on product properties using hot forming simulator[J], Journal of Materials Processing Technology, 2011,211:1441-1447.

Hot stamping is one of the hot forming processes for manufacturing products of lightweight construction such as lightweight vehicles. Knowledge on the characteristics of the hot stamping process is significant in designing and optimizing the process conditions, dies and tools; however, until now, the characteristics of this process, such as the relationships between a product property and die temperature and between a product property and cooling rate, and the springback amount, have not been clarified consistently or precisely. A new valuation method used to measure the effects of hot stamping conditions on product properties as a function of process parameters is proposed in this paper. This method utilizes a hot forming simulator, which is a precision press with feedback temperature control and controlled cooling, and permits to know the various characteristics of the hot stamping process. Here, the basic construction of the proposed method is presented, and its application to the characterization of the hot stamping process of high-strength steel sheets, such as an evaluation of the changes in product properties upon varying the forming conditions and process parameters, is shown and discussed.

热冲压是制造轻型汽车等轻量化结构产品的重要热成型工艺之一。了解热冲压过程的特点对于设计优化工艺条件、模具和工具具有重要意义；然而，直到目前为止，热冲压工程的特点，如产品特性与模具温度和冷却速率之间的关系，以及回弹量与模具温度和冷却速率之间的关系，还没有得到一致或准确的阐述。对此，本文建立了工艺参数的函数并提出了一种新的评价方法，这种方法可以用于衡量热冲压条件对产品性能的影响。该方法采用了一种热成型模拟器，这种热成型模拟器是一种具有反馈温度控制和控制冷却的精密压力机，它允许了解热冲压过程的各种特性。在本文中详细介绍了基本步骤，并讨论了其在高强度钢板热冲压工艺表征中的应用，如可用于在改变成形条件和工艺参数的情况下对产品性能变化进行评价。

16.Zhiying Sun, Lihui Lang. Study on hydroforming process and springback control of large sheet with weak rigidity[J], International Journal of Precision Engineering and Manufacturing, 2017,18(6):903-912.

The control of instability and springback about large sheet with weak rigidity is difficult in the process. The hydroforming process of aluminum alloy engine cover, springback prediction and compensation were analyzed, and the manufacturing method of parts with high precision was obtained.

In this paper, the effect of drawbead, pressure versus punch stroke, and blank holder force on the thinning rate of the plate was analyzed, and the phenomenon of wrinkling and fracture was judged according to the forming limit diagram. And springback is predicted through the method of the finite element and the surface of die was compensated by the iterative method.

The results show that the quality of large aluminum alloy plate with weak rigidity is improved, the cost of the mould is reduced by the compensation, and the period of mold repair and commissioning is reduced by the sheet hydroforming, which is the flexible manufacturing process. Springback of large aluminum alloy sheet with weak stiffness is within 10mm through process optimization, and the surface of die was compensated in local region. The springback not only has been effectively controlled, but the accuracy of dimensional also is more than 90% of ± 0.5 mm.

在冲压过程中，对于刚度较弱的大面积薄钢板，往往很难控制其失稳和回弹。因此，本文分析了铝合金发动机罩的液压成形，回弹预测和补偿，从而获得了高精度零件的制造方法。

本文分析了拉延筋，压力与冲头行程以及坯料夹持力对钢板减薄率的影响，并根据成形极限图判断了起皱和断裂现象。同时，本文通过有限元方法预测了回弹，并通过迭代法补偿了模具的表面。

经过验证，最终结果表明：我们成功提高了刚度较弱的大型铝合金板的质量，通过补偿降低了模具的成本，通过板材液压成形缩短了模具的修理和调试时间，这无疑是一种灵活的制造工艺。通过工艺优化，我们将刚度较弱的大型铝合金板的回弹控制在了10mm以内并局部补偿了模具的表面。这样不仅回弹得到了有效控制，而且尺寸精度也达到了±0.5毫米的90％以上。

17.C.Han, H.Feng, S.J.Yuan. Springback and compensation of bending for hydroforming of advanced high-strength steel welded tubes[J], The International Journal of Advanced Manufacturing Technology, 2017,89:9-12.

Bending springback plays an important role in hydroforming of curved hollow components, and the effect will be more apparent with the increase of the strength of the material. In order to predict and eliminate the effect of springback on hydroforming process, springback of DP590 welded tube was investigated in computer numerical control (CNC) bending process using theoretical analysis, numerical simulation, and experimental methods. The effects of the bending angles, the diameter-thickness ratio d/t, and the relative bending radius R/d on springback are studied, and the influence factor of the weld position is considered.

The theoretical and experimental results show that the springback of the DP590 welded tube with 65 mm in diameter and 2.6 mm in thickness varies within the range from 4.0 to 4.9 % and the amount of springback is influenced by the tube diameter and thickness. The springback reduces from 7.0 to 3.5% when the diameter-thickness ratio is increasing from 10 to 40. On the contrary, the springback increases from 3.7 to 7.2 % when the relative bending radius is increasing from 1.2 to 4.0. The effect of weld position on springback is very little, but it has a negative effect on defects of hydroforming and wall thickness distribution. It is liable to crack when hydroforming if the weld locates on the outside or neutral layer of the bend.

Finally, springback rules and weld effect are applied to form a control arm. A sound part had been successfully manufactured to avoid flash and crack defects considering the appropriate springback compensation and weld position.

弯曲回弹在弯曲空心部件的液压成形中起着重要作用，并且随着材料强度的增加，其效果更加明显。为了预测和消除回弹对液压成形过程的影响，本文采用理论分析，数值模拟和实验的方法，用计算机对DP590焊接管的回弹进行了数控（CNC）弯曲过程的研究。研究了弯曲角度，直径-厚度比d/t和相对弯曲半径R/d对回弹的影响，并考虑了焊缝位置这一影响因素。

最终，理论和实验的结果表明：直径为65毫米，厚度为2.6毫米的DP590焊接管的回弹在4.0％至4.9％的范围内变化，且回弹量受管直径和厚度的影响。当直径-厚度比从10增加到40时，回弹从7.0％降低到3.5％。相反，当相对弯曲半径从1.2到4.0增大时，回弹从3.7％增加到7.2％。同时，我们发现焊缝位置几乎不影响回弹，但对液压成形和壁厚分布的缺陷有负面影响。如果焊缝位于弯头的外部或中性层上，则液压成形时容易出现开裂。

最后，我们应用回弹规则和焊接效果形成了控制臂。考虑了适当的回弹补偿和焊缝位置的影响后，我们已经成功制造出了用以避免飞边和裂纹缺陷的声音部件。

18.Xiaohui Cui, Zhiwu Zhang, Zhihao Du, Hailiang Yu, Dongyang Qiu, Yongqi Cheng, Xiaoting Xiao. Inverse bending and springback-control using magnetic pulse forming[J], Journal of Materials Processing Tech, 2020,275:1-13.

In this study, electromagnetic-assisted stamping (EMAS) with magnetic-force reverse loading was introduced to control springback. Compared to conventional EMAS, this new method does not change the mold structure used in traditional stamping technology. Thus, this approach can greatly extend the operating lifetime of the mold and readily be adopted for commercial production. Results indicate that the equivalent plastic strain and the plastic dissipation energy increase, while the tangential stress and the elastic strain energy decrease considerably, with increasing in discharge-voltage. The simulation results accurately predict the sheet deformation for quasi-static stamping and dynamic magnetic pulse forming. Both simulations and experiments show that the angle after springback decreases with increasing in discharge-voltage.

在本次的研究中，我们引入了磁力反向加载的电磁辅助冲压（EMAS）以控制回弹。与传统的EMAS相比，这种新方法不需要更改传统冲压技术中使用的模具结构，因此，这种方法可以大大延长模具的使用寿命，并适用于商业生产。我们经过分析发现：当放电电压的增加时，当量塑性应变和塑性耗散能会增加，而切向应力和弹性应变能会显著下降。最终，我们的仿真结果准确地预测了用于准静态冲压和动态磁脉冲成形的薄板变形。并且仿真和实验结果均表明，回弹后的角度会随放电电压的增加而减小。

19.Jun Fang, Shiqiang Lu, Kelu Wang, Zhengjun Yao. Springback law of high-strength 21-6-9 stainless steel tube in numerical control bending under different process parameters[J], Proceedings of the Institution of Mechanical Engineers, 2017,231(10):1-10.

In order to achieve the precision bending deformation, the effects of process parameters on springback behaviors should be clarified preliminarily. Taking the 21-6-9 high-strength stainless steel tube of 15.88mm×0.84mm(outer diameter×wall thickness) as the objective, the multi-parameter sensitivity analysis and three-dimensional finite element numerical simulation are conducted to address the effects of process parameters on the springback behaviors in 21-6-9 high-strength stainless steel tube numerical control bending. The results show that

(1) springback increases with the increasing of the clearance between tube and mandrel C_m, the friction coefficient between tube and mandrel f_m, the friction coefficient between tube and bending die f_b, or with the decreasing of the mandrel extension length e, while the springback first increases and then remains unchanged with the increasing of the clearance between tube and bending die C_b.

(2)The sensitivity of springback radius to process parameters is larger than that of springback angle. And the sensitivity of springback to process parameters from high to low are e, C_b, C_m, f_b and f_m.

(3)The variation rules of the cross section deformation after springback with different C_m, C_b, f_m, f_b and e are similar to that before springback. But under same process parameters, the relative difference of the most measurement section is more than 20% and some even more than 70% before and after springback, and a platform deforming characteristics of the cross section deformation is shown after springback.

为了实现精确的弯曲变形，需要先弄清楚工艺参数对回弹过程的影响。我们以15.88mm×0.84mm（外径×壁厚）的21-6-9高强度不锈钢管为实验对象，进行了多参数灵敏度分析和三维有限元数值模拟以解决上述问题。最终发现工艺参数对21-6-9高强度不锈钢数控弯曲过程中回弹行为的影响如下所示：

（1）回弹量随着管与芯棒之间的间隙C_m，管与芯棒之间的摩擦系数f_m，管芯与弯曲模之间的摩擦系数f_b的增加而增加，随着芯棒延伸长度e的减小而增加，同时回弹量随着管与弯曲模之间的间隙C_b的增大而先增大后保持不变。

（2）回弹半径对工艺参数的灵敏度大于回弹角。回弹对工艺参数的灵敏度从高到低为e，C_b，C_m，f_b和f_m。

（3）对于不同的C_m，C_b，f_m，f_b和e，回弹后截面变形的变化规律与回弹之前相似。但是在相同的工艺参数下，最大测量截面回弹前后的相对差大于20％，有的甚至大于70％，而回弹后显示出了截面变形的平台变形特性。

20.赵艳龙,齐晓冬.高精度薄板冲压模具的设计与加工[J]，模具制造，2014,14(08):16-18.

压盘簧片是工业中常见的冲压制件，其制件材料为不锈钢，料厚为0.1mm，形状比较简单，但是制件尺寸公差、毛刺高度和平面度往往都有很高的要求，而制件的料厚和严格的公差要求决定了模具必须有很高的加工精度。

根据现代化冲压模具生产的实际需要，我们从模具设计和加工的角度出发，分析了高精度薄板冲压模具的设计、加工和生产中经常出现的问题点，并相应提出了解决方案。最终生产实际证明，改造后的模具不但提高了加工制件的精度，而且使模具的生产性能大幅提高，减少了模具的维修时间，提高了冲压设备的利用率。

21.杨忠炯,袁宏亮,周立强,姜东身.复杂空间曲面薄板冲压成形回弹预测[J]，长安大学学报(自然科学版)，2016,36(04):119-126.

为了预测复杂空间曲面薄板冲压成形的回弹，本文提出了一种基于薄板能量函数的复杂空间曲面薄板的冲压成形回弹预测方法。

首先通过粒子群优化算法得到毛坯直线在曲面上的映射，接着引入映射曲线上节点坐标参数ｕ，并将节点转化为控制顶点；然后将由控制顶点表示的曲面函数代入由板壳理论建立的薄板能量函数，借助最小能量原理建立曲面节点应变的解析参数方程，求解方程即能得到曲面各节点应变；最后利用塑性变形理论推导复杂空间曲面各节点的回弹量，拟合回弹后重新分布的节点就能得到回弹后曲面。

研究结果表明：基于能量函数的半解析半数值的薄板冲压回弹预测算法能够较为准确地预测复杂空间曲面薄板冲压成形的回弹，与现行的数值模拟法相比，简单易行，计算速度快，对复杂空间曲面预测具有一定的工程指导意义。

22.李健.镀镍薄板冲压成形过程中的回弹研究及稳健设计[D]，湘潭大学，2016.

镀镍薄板作为一种常见的镀层材料，在其冲压成型加工过程中，不可避免的会产生回弹现象，影响工件的成型精度和后续的装配质量。因此，对镀镍薄板冲压成型过程中的回弹研究具有很好的意义。本文就回弹这一失效现象，做了一些研究工作。

首先本文建立了镀镍薄板冲压成形的有限元模型并进行了数值模拟，得出了成型工件回弹前后的角度变化值；并且将镀镍薄板在万能试验机上进行冲压实验，测得成型零件的回弹角度，验证数值模拟对镀镍薄板冲压成型研究的可靠性。之后，针对压边力、摩擦系数、凸凹模间隙以及冲压速度对回弹的影响，本文设计了四因素四水平的正交试验方案，得到了工艺参数对镀镍薄板冲压成形过程中回弹角度的影响规律。然后进行了验证，得出多宽度高斯核函数模型比原径向基函数模型在预测精度与拟合精度上的优越性。最后，本文建立了镀镍薄板冲压成形回弹的稳健设计数学模型。结合多宽度高斯核函数模型，对镀镍薄板冲压成形过程中的回弹进行稳健设计，得出优化后的压边力和摩擦系数。并且在优化后的工艺参数的条件下，进行数值模拟，验证了基于多宽度高斯核函数模型的稳健设计方法在镀镍薄板冲压成形的回弹研究上是有效的。

23.尚琪,乔顺成,吴建军,张增坤,杨俊宙,邬洪飞,任银香.管件弯曲过渡区研究及回弹控制[J]，塑性工程学报，2020,27(01):38-45.

针对小直径厚壁管件，我们常常把成形部分沿长度方向划分为曲率过渡区和稳定区。通过有限元软件模拟工艺参数对管件成形过渡区曲率的影响，我们发现: 当进给速度的增大，管件过渡区曲率波动幅度会逐渐减小，波动区影响范围会逐渐增大；当弯曲速度增加50%，若进给速度增大，管件过渡区曲率波动幅度会增大，波动区范围会减小；当夹钳扭转速度增加，管件过渡区曲率波动幅度会逐渐减小，而波动区范围几乎不变。

使用数控弯曲设备进行试验，结果表明: 若弯曲半径比较大，则存在明显的管件曲率过渡区和曲率最大区；加工出的圆柱螺旋管件和空间变曲率管件位置偏差在合理范围内，基本满足设计和使用要求。

24.谢晖,唐长民,程威,张文彦,王东福.多弯角零件冲压回弹控制方法的研究[J]，塑性工程学报，2018,25(01):22-27.

针对多弯角类零件回弹大、影响因素多等特点，本文提出了一种综合考虑零件结构和工艺参数的控制多弯角零件回弹的方法。本文理论分析了回弹的原因，根据多弯角零件的特点，选出零件加强筋数目、压边力、圆角半径、型面夹角以及拉延筋系数5 个主要因子，通过 Box-Behnken 设计试验对各回弹影响因子的作用进行了探究。根据AutoForm软件仿真计算获得的样本点结果，本文研究了各因子对多弯角零件回弹的影响并在Isight中建立了响应面近似模型，用 Downhill Simplex 算法求解了近似模型的最优因子组合。最终利用优化后的中通道结构和工艺参数进行仿真验算，发现回弹绝对值的均值从原来的2.8mm降到了0.7mm，说明该方法能对多弯角零件回弹进行优化控制。

25.唐长民.多弯角车身件冲压回弹控制与同步工程技术研究[D]，湖南大学，2017.

高强度钢在力学性能上与普通钢具有一定的差别，它具有比普通钢更高的屈服强度，在满足同等安全性的条件下，高强度钢板零件可以采用更薄的材料，但是，高强度钢板的回弹严重影响了零件的成形性，降低了汽车的美观程度、装配效率和安全性，因此，回弹的研宄一直是冲压领域研究的重点问题。而在板料冲压回弹的问题中，多弯角零件的回弹由于回弹的累积效应，在冲压中，回弹显得更为明显，如果不解决该类问题，将会限制高强度钢的应用的普及。

针对上述问题，本文选用车身零件中最具代表性的多弯角零件中通道为研宄对象，采用冲压数值模拟方法，在一定的压边力和拉延筋系数等工艺参数条件下，研究弯角半径、侧壁斜度、加强筋数目对回弹的影响，使在零件设计初期就考虑零件的成形性，使零件成形质量最优。通过该种方法，可以在车身开发时就考虑零件的成形性，控制零件成形时的回弹，减少后期的工艺调整和模具修正的时间和精力，达到节约生成成本和提高生成效率的目的。本文提出的方法，丰富了车身开发的同步工程技术，为冲压回弹控制有一定的启示作用。

26.周文浩. 板料弯曲回弹控制及数值模拟精度研究[D]，哈尔滨理工大学，2015.

近些年来，高强度钢的应用越来越广泛。目前，高强度钢冲压成形中最为严重的问题就是回弹。虽然数值模拟技术发展至今对板料成形中的破裂和起皱等缺陷已经能够预测的较为准确，但对于回弹的预测精度仍不尽人意。

对于回弹预测精度不准确的问题，本文提出了模拟成形精度与数值模拟精度这两种不同的概念，提出了通过改变工艺参数条件提高模拟成形精度和改变模拟参数条件提高数值模拟精度的观点。本文研究了数值模拟过程中冲压速度、压边力和模具间隙，分析其对模拟成形精度的影响。通过比较模拟成形精度可以得出：冲压速度越快，模拟结果越接近标准；压边力越大，模拟结果越接近标准值；模具间隙越小，模拟结果越接近标准值。对以上三种工艺参数进行优化，得到最优的实验条件并进行实际实验。在优化过工艺参数的基础上改变积分点个数和单元网格大小这两个模拟参数，通过比较数值模拟精度可以得出：单元网越小，模拟结果越接近实验结果，积分点个数越大，模拟结果越接近实验结果。

27.薛冰冰,刘和平,何聪.薄壁箱形金属管材冲压成形试验研究[J]，机床与液压，2015,43(07):32-34.

薄壁矩形钢管是一种用途广泛、经济实用的异形结构管材，与其他截面种类的钢管相比，具有质量轻、抗变形强度高、抗弯模量大、节省材料等优点。以薄壁箱形金属管材为对象，本文研究了冲压成形过程中冲压速度、约束条件等因素对成形质量的影响。研究表明: 冲压过程中增加薄壁箱形管材侧壁约束可以提高薄壁箱形管坯整体受压变形的稳定性，利用侧壁挡板和内腔充沙等措施，可明显减弱管坯产生侧壁屈曲；合适的冲压速度可有效消除管坯顶面屈曲；合理控制冲压速度和约束条件等工艺参数可有效提高薄壁箱形金属管材冲压成形质量。