【摘要】 针对多工艺参数影响下的新能源汽车电机铁芯成型精度偏差问题，通过剖析了新能源汽车电机超薄铁芯散片冲裁及其扣点拉深过程，以薄片厚度0.5 mm的转子铁芯散片为对象，研究冲裁速度、冲裁间隙、摩擦因子、压边状态4个工艺参数对散片成型及其扣点精度的影响，并进行仿真计算分析，应用正交试验法进行铁芯散片及其扣点拉深成形精度试验，将最大应力和变形量作为试验评价指标，完成4因素2水平的正交试验。基于试验结果的极差和方差统计数据分析各工艺参数对精度的影响程度，得到了最优工艺参数组合，以实现在高速级进冲裁工况下的散片及其扣点成形精度控制。结果表明：当冲裁速度为7 000 mm/s、冲裁间隙为1%料厚、摩擦系数为0.1、压边力为50 kN时，可获得散片成型及其扣点拉深成型精度的最优，有效地提高了试模效率，达到了控制电机铁芯超薄高速级进冲裁散片及其扣点成型精度的目的。更多还原

【Abstract】 The forming accuracy of motor iron cores of new vehicle energy has significant differences due to the influence of multiple factors. An effective precision control method was proposed for high-speed progressive blanking forming of ultra-thin loose pieces of motor iron cores and precision control of button forming that affects stacking forming accuracy. A thorough analysis was conducted on the blanking and fastening process of ultra-thin iron core loose pieces for new energy vehicle motors. The effects of four process parameters, including blanking speed, blanking clearance, friction factor, and edge pressing stated on a rotor iron core loose piece with a thickness of 0.5 mm, were investigated. The forming and fastening accuracy of loose pieces were simulated and analyzed. The orthogonal experimental method was employed to conduct precision tests on the forming of iron core loose pieces and their fastening points with maximum stress and deformation as experimental evaluation indicators. A 4-factor, 2-level orthogonal experiment was performed. Based on the range and variance statistical data of experimental results, the influence of various process parameters on accuracy was analyzed, and the optimal combination of process parameters was determined to achieve the precision control of loose pieces and fastening points under the high-speed progressive blanking conditions. The results indicated that the optimal precision for loose pieces forming and the deep drawing of fastening points can be achieved when the blanking speed was 7 000 mm/s, the blanking gap was 1% of material thickness, the friction coefficient was 0.1, and the edge holding force was 50 kN. This effectively enhanced trial mold efficiency and achieved the goal of controlling precision in ultra-thin high-speed progressive blanking of motor iron cores for loose pieces forming and fastening point forming.更多还原