Stamping test and simulation analysis of shock absorber mounting end

ObjectivesIn order to reduce the development difficulty of the shock absorber installation end and the problems encountered in the mold processing design，Methodsthe main plate body and outer sleeve of the installation end of a shock absorber were selected as the research objects， and the numerical simulation was carried out by Dynaform software. The friction coefficient， clamping speed， drawing speed and die clearance， which had great influence on the forming quality of the main plate body， were selected as the main factors to design the orthogonal test. The maximum thinning rate was used as the evaluation index to solve the optimal stamping process parameter combination of the main plate body forming. The forming quality of the outer sleeve was optimized by the method of early puncture. The mechanics， thickness and air tightness of the actual production installation end were tested.ResultsThe optimal combination of stamping process parameters for the main plate forming was obtained， the friction coefficient was 0.145， the closing speed was 2 000 mm/s， the drawing speed was 1 000 mm/s and the die clearance was 2.1 mm. On this basis， numerical simulation and production verification were carried out. In the numerical simulation， the maximum thinning rate of the main plate was 17.175%，and the maximum thickening rate was 53.061%. The maximum thinning rate of the outer sleeve was 13.770%，and the maximum thickening rate was 58.320%， which could meet the design requirements. In the production test， the surface quality of the end was good during the mechanical test，and there was no deformation， obvious wrinkling and cracking. The maximum deviation between the experimental wall thickness and the simulated wall thickness of the end in the thickness test was 6.8%， which was basically consistent with the numerical simulation results. In the air tightness test，there was no air leakage at the end under the condition of internal stamping of 1.6 MPa and standing for 30 s.ConclusionsThe research showed that the comprehensive performance of the installation end could meet the requirements， and the correctness of the process setting sequence in the end forming was verified. The research results could provide some theoretical guidance for the research and development of shock absorber installation end.