Abstract: The baking deformation of door spraying process has always been a complex and difficult problem in the industry. In order to solve this problem, this paper puts forward the effective improvement countermeasures. Taking a vehicle door assembly as an example, through physical verification test, 3D measurement and other methods, the change of geometric dimension of the spraying process is tracked and the baking deformation law is studied. Then, the reasons of baking deformation are analyzed from the design structure and manufacturing process of door such as door inner plate, door guide rail, hinge nut plate and so on. In the early design stage, it is proposed to adopt the welding processes such as door inner plate welding, unilateral spot welding after door assembly edging, and separating spot welding between door hinge reinforcing plate and guide rail. In the stage of vehicle industrialization commissioning, it is proposed to correct the door welding fixture and adjust the hinge nut plate to compensate the baking deformation. By the real vehicle verification, this research result improves the appearance gap flush, which is of great significance to improve the perceived quality level of the whole vehicle and reduce customer complaints. At the same time, it also provides a reference for the improvement of baking deformation of tailgate, hood and other opening and closing parts.

Key words: Baking deformation; Front door assembly; Appearance gap flush; Improvement strategies

摘要： 车门喷涂过程的烘烤变形一直以来属于业界复合型疑难问题，文章为了解决此问题， 提出行之有效的改善对策。以某车型车门总成为例，通过实物验证试验，3D 测量等方式，跟 踪其喷涂过程几何尺寸的变化，研究其烘烤变形规律。然后从车门里板、车门导轨、铰链螺 母板等车门设计结构和制造工艺分析其烘烤变形的原因。在前期设计阶段，提出采用车门里 板拼焊、车门总成包边后单边点焊、车门铰链加强板与导轨分开点焊等焊接工艺，在车型工 业化调试阶段，提出车门焊接夹具矫形、铰链螺母板匹配调整，补偿烘烤变形量。经过实车 验证，此研究成果改善了外观间隙面差，对于提升整车感知质量水平，减少客户抱怨具有重 大意义，同时也为尾门、发动机罩等开闭件烘烤变形的改善提供参考。

关键词: 烘烤变形；前车门总成；外观间隙面差；改善策略