Adaptive Blank Holder Control Deep-Drawing Process Using Vibration Tooling Without Lubricant

为了开发一种具有高柔性和高产品质量的新型拉深工艺，实现无润滑剂成形过程(即所谓的“干成形过程”)或无清洗油过程，本项目对自适应压边机控制方法与振动模具技术相结合进行了两年的研究。(1)首先，更新和开发了一套新的自适应压边力控制系统，将PC/DOS计算机替换为PC/DOS计算机，并将其接口改为新的高精度、高分辨率、高速度的控制系统。(2)利用该系统，对厚度为1.0 mm的薄板(SPCD)进行了无润滑低振动压边力拉深试验。结果表明，压边力和成形能在压边力幅值较大的情况下比振动频率较高的情况下下降得更多。为了验证有限元模拟振动拉深成形过程的有效性，采用PC/LS-DYNA动力显式有限元方法对振动拉深成形过程进行了数值模拟，模拟结果与实验结果吻合较好。结果表明，有限元仿真是预测合适的振动条件、提前评估带振模糊自适应压边力控制系统及振动效果的良好设计工具。

In order to develop a novel deep drawing process with high flexibility and high product quality achieving no lubricant forming process (so-called "dry forming process") or without cleaning oil process, adaptive blank holder control method combined with vibration tooling technique was studied in this project for two years. The following conclusions were obtained in this study.(1) First of all, a newly developed adaptive blank holder force (BHF) control system was renewed and developed, whose computer was replaced to PC/DOS machine and its interface was also changed into a new one with high accuracy and resolution, and high-speed.(2) Using this machine, a deep-drawing test with low vibration blank holder was carried out under no lubricant for a steel sheet (SPCD) with 1.0mm thickness. As a result, it is clarified that the forming force and forming energy decrease more in the case of large vibrating amplitude of BHF than those of high vibrating frequency. The result implies that the product is capable to have high quality of product surface.(3) To confirm the effectiveness of FEM simulation for the vibrating BH deep-drawing process, the dynamic explicit finite element method was employed, PC/LS-DYNA.The results of simulation are in good agreement with the experimental results. The result shows that the FEM simulation is a good design tool to predict the suitable vibration conditions and to evaluate in advance the fuzzy adaptive BHF control system with vibration and the effect of vibration.