基于网格映射的车身覆盖件精细模面设计研究

由于机台和模具变形、制件减薄等因素的影响，造成合模时模面间隙与板料成形零件厚度不一致而导致模具研合率低.针对上述问题提出了一种新的模具模面精细化补偿方法，针对该补偿方法提出了一种基于二分法的网格变量映射新算法来实现不同网格变量之间的精确映射.该设计补偿方法在工艺设计阶段即可对模具型面进行相应的变形补偿，以抵消实际模具结构变形对成形件质量的影响.应用实例表明，该映射算法在精度和速度上有较大的提高，该补偿方法能够解决模具调试阶段研合率低的问题, 大大提高了首次合模率.
Due to the impact of the elastic deformation of tools and press, and the blank thinning and other factors, the die surface gap is not consistent with the thickness distribution of the stamped part, which leads to low spot rate. With regard to the problem mentioned above, a new mesh mapping algorithm based on binary search was presented, which can realize the accurate mapping between different meshes，and then, a new methodological scheme was developed for the compensation of the die surfaces. In the early design stage, the new methodology can guide the engineer to modify the die surface, thus offsetting the influence on quality caused by the deformation of tools. Application example has shown that the new mapping algorithm not only improves the accuracy but also improves the search speed. The methodology can solve the problem of low spot rate and noticeably improve the first time contacting ratio.