A process for optimizing the quality of the flange surface of a fender wheel opening

Abstract

This invention discloses a process method for optimizing the surface quality of the fender flange at the wheel arch of a fender, belonging to the field of fender manufacturing technology. This method involves adding a three-point material storage bag during the drawing process. Specifically, a three-point material storage bag is designed on the process supplementary surface outside the fender line. The distance of the three-point material storage bag from the fender line is determined based on the specific parameters of the fender shape at the wheel arch, the proportional relationship between the small claw fender height D, and the fender height E of adjacent locations. The relative positional relationship of the three-point material storage bag is determined based on the relative positions of the hole diameter R3 on the small claw and the distances F, G, and H from the three boundaries. This invention can ensure the forming quality of the part during the production process, reduce the risk of defects after fendering, and solve problems such as uneven rounded corners and surface finish.

Description

Technical Field

[0001] This invention belongs to the field of fender manufacturing technology, specifically relating to a process method for optimizing the quality of the fender flange surface of the wheel well. Background Technology

[0002] Due to the product design at the fender wheel arch, the flange height varies. During the stamping process, the radius (R) of the small claw at the wheel arch experiences significant upward arching during flange turning, resulting in an uneven rounded corner and surface defects. The fender wheel arch area overlaps with plastic trim parts, requiring high surface quality. Surface defects can only be gradually optimized through adjustments, a method demanding high skill levels and workload, increasing the difficulty of later mold adjustments and raising the risk of defects, significantly impacting the overall appearance of the vehicle. The flange turning at the fender wheel arch is a case of insufficient material turning, and the varying flange heights lead to uneven stress during turning, resulting in a noticeable upward arching of the rounded corner at the small claw with the higher flange height, along with significant surface defects on surface A near the small claw. Figure 1 As shown. The main drawback of this problem is that the rounded corners of the part are not smooth after flanging, and there are surface defects on surface A of the part, which increases the difficulty of later debugging and prolongs the debugging cycle. Summary of the Invention

[0003] To address the aforementioned deficiencies in existing technologies, this invention provides a process method for optimizing the surface quality of fender flange edges. This method is based on research into the product shaping at the fender flange, the unevenness of the rounded corners after flangering, and the principles behind surface defects. It offers an effective solution that ensures the forming quality of the parts during production, reduces the risk of defects after flangering, and resolves issues related to uneven rounded corners and surface defects. Based on conventional stamping processes, this invention optimizes the process shaping as follows: 1. Drawing process: Adding a three-point material storage bag to alleviate the upward arching of rounded corners during straight flangering; 2. Three-point material storage bag shaping parameters and distribution: Designing a reasonable process shape based on different flange heights for the product, and simultaneously applying CAE technology for simulation analysis and optimization of the process shape.

[0004] This invention is achieved through the following technical solution:

[0005] A process method for optimizing the quality of the fender flange surface of a fender wheel opening includes: a first step: drawing forming; a second step: trimming; a third step: straight fendering; a fourth step: wedge fendering; and a fifth step: wedge punching. Specifically, a three-point material storage bag is added to the drawing forming process. The three-point material storage bag is designed on the process supplementary surface outside the product fender line. The distance between the three-point material storage bag and the fender line is determined based on the specific parameters of the fender shape at the fender wheel opening, the ratio of the small claw fender height D to the adjacent fender height E. The relative positional relationship of the three-point material storage bag is determined based on the relative positions of the hole diameter R3 on the small claw and the distances F, G, and H from the three boundaries.

[0006] Furthermore, on the process supplement surface outside the product flange line, three material storage bags are evenly distributed according to the unfolding line position of the small claw at this position of the fender. Among them, two material storage bags are ensured to be equidistant from the flange line; the third material storage bag is located slightly below the middle of the first two material storage bags, avoiding the punching position on the small claw.

[0007] Furthermore, the distance between the two storage bags and the flange line is 3mm.

[0008] Furthermore, the height of the storage bag should be 1.5-2mm, which should be lower than the A side of the fender to avoid contact with this position first during the drawing process, which could cause scratches on the sheet metal.

[0009] Furthermore, the radius of the ball corner W of the storage bag is 5mm or more, and the radius of the chamfer R1 is R5mm to avoid concentrated stress and strain in the sheet metal during the forming process due to the small radius, which would result in serious corner marks on the storage bag after flanging.

[0010] Furthermore, the process design parameters of the three-point storage bag were simulated and verified using CAE technology, thereby obtaining the optimal parameter settings.

[0011] Furthermore, when using CAE technology for simulation and verification, the following conditions must be met:

[0012] A. When the flanging begins, the straight flanging inlay must first contact the flanging line position and not the three-point storage bag, otherwise the "rushing" situation may occur.

[0013] B. During the flanging process, when the straight flanging insert contacts the three-point storage bag, check whether the flanging rounded corner is arched. If this occurs, the position of the three-point storage bag needs to be adjusted so that the straight flanging insert contacts the three-point storage bag earlier.

[0014] C. When the flanging is finished, check if there is excessive material on the flanged surface. If so, the height of the storage bag needs to be reduced.

[0015] Compared with the prior art, the advantages of the present invention are as follows:

[0016] 1. Through research on the product shape at the fender wheel opening, the uneven rounded corners after flanging, and the principles of surface defects, a reasonable process shape is adopted in the process design stage. A three-point material storage bag is added to alleviate the uneven force caused by different flanging heights during the straight flanging process, which leads to the upward arching of the rounded corners. This solves the defect of uneven rounded corners, shortens the mold development cycle, and also reduces the technical requirements for staff. It can significantly reduce the amount of debugging work, shorten the rectification cycle, and the process method is convenient and simple.

[0017] 2. During the process design phase, CAE technology is used for simulation analysis to fully demonstrate the rationality of the process design, ensure the accuracy and reliability of the formability and the quality of the rounded corners after flanging, and guide the debugging work.

[0018] 3. In the later process of improving the quality of the parts, the defect of uneven rounded corners after flanging can be optimized by adjusting the height of the three-point storage bag. This reduces other defects caused by the use of complex rectification methods such as welding and milling during the process of improving the quality of the parts, greatly reducing the difficulty of improving the quality of the parts and reducing the increase in processing and manufacturing difficulty and cost.

[0019] 4. The flanges and rounded corners at the wheel wells of the fenders using this invention are smooth, and the surface quality meets the industry's Auditer standards. Attached Figure Description

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0021] Figure 1 This is a schematic diagram showing the rounded corners arched upwards after the flange is turned up;

[0022] Figure 2 A schematic diagram of the three-point material storage bag process;

[0023] Figure 3 A schematic diagram showing the absence of an upward arch in the rounded corners of the flange after theoretical analysis of the optimized process design;

[0024] Figure 4 A schematic diagram showing the output state after process optimization and part preparation;

[0025] Figure 5 This is a schematic diagram of a fender product.

[0026] Figure 6 A schematic diagram showing the parameters of the flange height at the wheel arch of the fender;

[0027] Figure 7A schematic diagram of the fender drawing process.

[0028] Figure 8 A schematic diagram of the various parameters for the three-point material storage bag process is provided.

[0029] Figure 9 This is a schematic diagram of the straight flanged inlay at the initial stage of flange turning;

[0030] Figure 10 A schematic diagram showing the state when the straight-edged inlay contacts the three-point storage bag;

[0031] Figure 11 This is a schematic diagram showing the state of the straight-edged inlay block after the flanging is completed.

[0032] In the diagram: 1. Straight flange insert, 2. Pressure plate, 3. Lower punch, 4. Molded part. Detailed Implementation

[0033] To clearly and completely describe the technical solution and its specific working process of the present invention, the specific embodiments of the present invention are as follows, in conjunction with the accompanying drawings:

[0034] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0036] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0037] Example 1

[0038] This embodiment provides a process method for optimizing the quality of the fender flange surface of a fender wheel well, including: a first step: drawing forming; a second step: trimming; a third step: straight fendering; a fourth step: wedge fendering; and a fifth step: wedge punching. In the drawing forming step, a three-point sump is added, the arrangement of which is as follows: Figure 2 As shown; specifically, a three-point material storage bag is designed on the process supplement surface outside the product flange line. The distance of the three-point material storage bag from the flange line is determined based on the specific parameters of the flange shape at the fender wheel opening, the flange height D of the small claw, and the proportional relationship between the flange height E of adjacent locations. The relative positional relationship of the three-point material storage bag is determined based on the relative positions of the hole size R3 on the flange small claw and the distances F, G, and H from the three boundaries. After optimization, the flanged rounded corners have no upward arching. The theoretical simulation state is as follows. Figure 3 As shown, the on-site dispatch status is as follows: Figure 4 As shown.

[0039] In this embodiment, three storage bags are evenly distributed on the process supplement surface outside the product flange line according to the unfolding line position of the small claw at this position of the fender. Among them, the positions of two storage bags are equidistant from the flange line; the third storage bag is located slightly below the middle of the first two storage bags, avoiding the punching position on the small claw.

[0040] In this embodiment, the distance between the two storage bags and the flange line is 3mm.

[0041] In this embodiment, the height of the storage bag is 1.5-2mm, which needs to be lower than the A side of the fender to avoid contact with this position first during the drawing process, which could cause scratches on the sheet metal.

[0042] In this embodiment, the radius of the ball corner W of the storage bag is R5mm or more, and the radius of the ball corner W and the process supplementary chamfer Y is 5mm. This avoids the sheet material from generating concentrated stress and strain during the forming process due to the small rounded corner, which would result in severe rounded corner marks on the storage bag after flanging.

[0043] In this embodiment, the process design parameters of the three-point storage bag were simulated and verified using CAE technology to obtain the optimal parameter settings.

[0044] In this embodiment, when using CAE technology for simulation verification, the following conditions must be met:

[0045] A. When the flanging begins, the straight flanging inlay must first contact the flanging line position and not the three-point storage bag, otherwise the "rushing" situation may occur.

[0046] B. During the flanging process, when the straight flanging insert contacts the three-point storage bag, check whether the flanging rounded corner is arched. If this occurs, the position of the three-point storage bag needs to be adjusted so that the straight flanging insert contacts the three-point storage bag earlier.

[0047] C. When the flanging is finished, check if there is excessive material on the flanged surface. If so, the height of the storage bag needs to be reduced.

[0048] Example 2

[0049] This embodiment provides a process method for optimizing the quality of the fender flange surface of a fender wheel well, including: first step: drawing forming; second step: trimming; third step: straight fendering; fourth step: wedge fendering; fifth step: wedge punching. The process design is optimized as follows: 1. Drawing forming process: adding a three-point material storage bag to alleviate the rounded corner arching phenomenon during the straight fendering process; 2. Three-point material storage bag design parameters and distribution position: designing a reasonable process design by considering different fendering heights of the product, and applying CAE technology for simulation analysis to adjust and optimize the process design.

[0050] Analysis of product styling and drawing simulation results based on long-term accumulated experience reveals that when the flanging rounded corners arch upwards, uneven stress caused by varying flanging heights during the straight flanging process, and adjustments to the outer surface of the drawing die to supplement the styling, can be used individually or in combination to control this uneven stress and prevent the rounded corners from arching after flanging. While this method can solve the problem to some extent, adjusting the flanging height or eliminating the small claws at the fender wheel opening would alter the original product design concept and be detrimental to vehicle matching requirements. Only by adjusting the outer surface of the product to supplement the styling can the arching of the rounded corners after flanging be optimized and controlled.

[0051] When designing the three-point storage bag process, the shape of the three-point storage bag is first designed on the process supplement surface outside the product's flange line. The specific location of the three-point storage bag needs to be determined based on the specific parameters of the flange shape at the fender wheel opening. The ratio between the flange height D of the small claw and the flange height E of the adjacent location directly determines the distance of the storage bag from the flange line. The relative positions of the hole size R3 on the flange small claw and the distances F, G, and H from the three boundaries directly determine the relative positional relationship of the three storage bags. The general design principle of the three-point storage bag is to evenly distribute three storage bags on the process supplement surface outside the product's flange line according to the unfolded line position of the small claw at this location. Two of the storage bags need to be equidistant from the flange line, preferably 3mm. The third storage bag is located slightly below the middle of the first two storage bags, usually avoiding the punching holes on the small claw. Location; the height of the storage bag is generally required to be 1.5-2mm, provided that it is lower than the A side of the product to avoid contact at this position during drawing and forming, which could cause scratches on the sheet metal; the ball corner R2 of the storage bag should be R5mm or more, and the ball corner R2 and the process supplementary chamfer R1 should be R5mm to avoid concentrated stress and strain on the sheet metal during forming due to too small a radius, resulting in severe rounded corner marks on the storage bag after flanging; the relative positional relationship A, B, C between the three-point storage bags needs to be based on the size of the hole R3 on the flanging claw and the relative position of the distances F, G, H from the three boundaries; the process shape parameters of the three-point storage bag designed according to the basic principles need to be simulated and verified by CAE technology to obtain the most reasonable size and layout. During CAE simulation verification, the forming process is mainly analyzed using cross-sectional diagrams of the working relationship between the straight flanging insert 1, pressure plate 2, lower punch 3, and forming part 4 to determine if the forming process meets the requirements. A thorough analysis of the contact situation during the flanging process of the flanging is conducted. Firstly, the straight flanging insert 1 must contact the flanging line position at the very beginning of the flanging process; it cannot contact the three-point material storage bag first, otherwise a "rushing" situation will occur. Figure 9 As shown; secondly, during the flanging process, when the straight flanging insert 1 contacts the three-point storage bag, check if the flanging rounded corner has arched upwards. If this occurs, the position of the three-point storage bag needs to be adjusted so that the straight flanging insert contacts the three-point storage bag earlier. Figure 10 As shown; finally, when the flanging is finished, check if there is excessive material on the flanged surface. If so, the height of the storage bag needs to be reduced. Figure 11 As shown.

[0052] See Figure 5 A schematic diagram of the fender product; the diagram shows the distribution of the flanges at the wheel well and the position of the flange claws;

[0053] See Figure 6 A schematic diagram showing the parameters of the flange height at the wheel arch of the fender; the flange height and the parameters of the flange claw shown in the diagram;

[0054] See Figure 7A schematic diagram of the fender drawing process; the overall effect of the three-point material storage bag in the process design shown in the figure;

[0055] See Figure 8 A schematic diagram of the parameters of the three-point material storage bag process; the diagram shows the parameters of the three-point material storage bag itself and the relative positions of the three components;

[0056] In this embodiment, a process method for optimizing the quality of the fender flange surface is adopted, and the optimized parameters are as follows:

[0057] When the flange height D = 30mm, the flange height E = 10mm at adjacent locations, and the aperture U on the flange claw = 4mm, the distances F = 10mm, G = 7mm, and H = 10mm from the aperture U on the flange claw to the three boundaries;

[0058] Proportional relationships of key parameters:

[0059] D / E≤3:1, F / U≤2.5; H / U≤2.5; G / U≥1.75mm;

[0060] Optimized three-point material bag positions: A = 10mm; B = 10mm; C = 7mm; Y = 4mm; W = 5mm;

[0061] Proportional relationships of key parameters:

[0062] C / U ≥ 1.75 mm; 1.75 ≤ A / U ≤ 2.5; 1.75 ≤ B / U ≤ 2.5; Y and W are constant values.

[0063] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0064] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0065] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A process method for optimizing the quality of the flanged surface of a fender wheel well, characterized in that, The process includes: First step: drawing forming; Second step: trimming; Third step: straight flanging; Fourth step: wedge flanging; Fifth step: wedge punching. In the drawing forming process, a three-point material storage bag is added. Specifically, three material storage bags are evenly distributed on the process supplement surface outside the product's flanging line, according to the unfolding line position of the fender claw. The process design parameters of the three-point material storage bag are simulated and verified using CAE technology to obtain the optimal parameter settings. The distance between the three-point material storage bag and the flanging line is determined based on the specific parameters of the flanging design at the flanging wheel opening, the ratio of the flanging height D of the small claw to the flanging height E of adjacent locations. Two of the material storage bags are equidistant from the flanging line and 3mm apart, while the third material storage bag is positioned slightly below the middle of the first two, avoiding the punching position on the small claw. The relative positional relationship of the three-point material storage bags is based on the hole diameter R3 on the flanging small claw. The relative positions of the distances (F, G, H) between the edge of the mounting hole on the flanged claw and the three boundaries of the flanged claw are determined. When using CAE technology for simulation and verification, the following conditions must be met: A. When the flanging begins, the straight flanging inlay must first contact the flanging line position and not the three-point storage bag, otherwise the "rushing" situation may occur. B. During the flanging process, when the straight flanging insert contacts the three-point storage bag, check whether the flanging rounded corner is arched. If this occurs, the position of the three-point storage bag needs to be adjusted so that the straight flanging insert contacts the three-point storage bag earlier. C. When the flanging is finished, check if there is excessive material on the flanged surface. If so, the height of the storage bag needs to be reduced.

2. The process method for optimizing the quality of the fender flange surface as described in claim 1, characterized in that, The height of the storage bag should be 1.5-2mm, and it must be lower than the A side of the fender.

3. The process method for optimizing the quality of the fender flange surface of a fender as described in claim 1, characterized in that, The radius of the spherical corner W of the storage bag is 5mm or more, and the radius of the process supplementary chamfer R1 is R5mm.

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