某轿车SUEA导轨有限元模拟分析及优化

Finite Element Simulation and Optimization of the SUEA Rail for a Certain Automobile

摘要: 针对某轿车SUEA导轨翻边开裂的问题，基于Autoform软件开展有限元模拟，系统分析该导轨的开裂成形机理，揭示了导致开裂缺陷的主要原因。研究表明：开裂处位于内凹外缘翻边区域，该处材料变形剧烈，在切向拉应力的主导作用下发生显著的切向伸长变形，当切向拉应力超出板料的成形极限时，材料发生过度减薄导致开裂。通过合理优化工序，并对摩擦系数、压边力和拉延筋系数等工艺参数进行优化，优化后零件大部分区域处于成形极限曲线下方的安全范围内，且减薄率、起皱区域和开裂区域得到明显改善，显著提升了零件整体成形质量。

Abstract: Addressing the issue of flanging cracking in a certain automobile SUEA rail, finite element simulations were conducted using Autoform software to systematically analyze the fracture forming mechanism of the rail and reveal the primary causes of the cracking defect. The results indicate that the fracture occurs in the concave outer edge flanging area, where the material undergoes severe deformation, characterized by significant tangential elongation under the dominant effect of tangential tensile stress. When the tangential tensile stress exceeds the forming limit of the sheet metal, excessive thinning occurs, leading to fracture. Through the rational optimization of the process sequence and the key process parameters including friction coefficient, blank holder force, and drawbead restraining force, the majority of the part falls within the safe zone below the forming limit curve. Consequently, the thinning rate, wrinkling tendency, and cracking risk are significantly improved, thereby markedly enhancing the overall forming quality of the component.