在门盖件滚压成形中,非金属折边胶层以及轻质金属与折边胶的交互作用影响门盖的制造精度和性能,为汽车车身薄板含胶滚压成形及其质量控制研究带来显著困难.为此,建立基于有限元-光滑粒子流体动力学法(FEM-SPH)的铝合金薄板含胶滚压成形数值分析模型.利用SPH模拟折边胶挤压流动过程,结合FEM建立含胶薄板的滚压仿真模型.搭建含胶铝合金薄板的两道次滚压成形实验平台,以滚边损耗量和表面波浪系数为滚压成形质量指标,分析验证数值模型的有效性.基于正交试验法研究首末道次之间的质量变化,以及影响质量的关键工艺参数.结果表明:与首道次相比,末道次的滚边损耗量降低、表面波浪系数变小;影响表面波浪系数的工艺参数由大到小依次为翻边高度、圆角半径、TCP-RTP值、滚轮直径;影响滚边损耗量的工艺参数由大到小依次为TCP-RTP值、圆角半径、翻边高度、滚轮直径.构建的滚压成形质量与工艺参数之间的拟合关系能够支持含胶铝合金薄板的滚压成形质量预测.

In the roll-hemming forming process of door cover, the non-metallic flanging adhesive and the interaction between light metal and flanging adhesive will affect the manufacturing accuracy and performance of the door cover, and increase the difficulty of roll-hemming forming and quality control of automobile body sheet with adhesive. Therefore, a numerical analysis model for roll-hemming forming of aluminum alloy sheet with adhesive was proposed based on the finite element method and the smooth particle hydrodynamic (FEM-SPH) method. First, SPH was used to simulate the extrusion flow process of the flanging adhesive, and a roll-hemming simulation model of sheet metal with adhesive was established in combination with FEM. Then, an experimental platform for two-pass roll-hemming forming of aluminum alloy sheet with adhesive was built, and the roll-hemming loss and surface wave coefficient were taken as the roll-hemming forming quality index to analysis and verify the validity of the numerical model. After that, the quality change between the first pass and the last pass and the key process parameters affecting quality were studied based on the orthogonal test method. Finally, the fitting relationship between roll-hemming forming quality and process parameters was established. The results show that the roll-hemming loss and the surface wave coefficient of the last pass are reduced compared with the first pass. The process parameters that affect the surface wave coefficient in descending order are flanging height, fillet radius, TCP-RTP value, and roller diameter. The process parameters that affect the roll-hemming loss in descending order are TCP-RTP value, fillet radius, flanging height, and roller diameter. The fitting relationship can support the prediction of roll-hemming forming quality of aluminum alloy sheet with adhesive.