铝合金车身窗框亮条端头形状复杂，外形尺寸约为1000mm×30mm，厚度约1mm，沿宽度方向截面较窄，为复杂的变曲率凸截面，翻边后易出现圆角不均匀缺陷，影响表面质量.通过模拟和试验研究发现，随着凹模圆角半径的减小，亮条产品圆角不均匀缺陷得到一定程度的改善，但尚未达到理想指标.基于这一结论，提出了变圆角半径凹模解决方案及对应的凹模设计流程.模拟和试验研究表明：按照设计流程合理规划凹模圆角半径，采用凹模脊部圆角半径较小，向两侧逐渐增大的方式，减小了翻边后亮条产品不同截面圆角半径的极差值和方差值，达到了产品理想指标.
The shape of the end of window trim strip is complex, the dimension is about 1000mm×30mm, the thickness is about 1mm, and the cross section in the width direction is narrow, which is a complex variable curvature convex section. The uneven fillet radius defect appeared at the end of window trim strip in the flanging process severely influenced its surface quality. Through simulations and tests, it is found that when the die radius is reduced, the defect of uneven fillet of the window trim strip is improved to some extent, but it has not reached the ideal index. Based on this conclusion, a die with variable fillet radius is designed to solve this problem and raised its design procedure. This die can solve this defect by reasonably arranging the die fillet radius. The fillet radius of the die is smaller in the center and gradually increases from center to corner. The simulation and test results showed that this method remarkably reduces the difference and variance of the fillet radius in different cross-sections of window trim strip.
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