Abstract: In recent years, with the high-end transformation of the truck industry, the market's requirements for truck lightweight have become one of the important technological breakthrough directions, and the research on aluminum alloy material substitution without changing the original body manufacturing system has become a hot topic. How to more effectively control the cost of trial production and verification, and reduce the initial investment cost and process verification cycle of the mold as much as possible, is the key concern of the lightweight project. Computer aided engineering (CAE) forming analysis technology is used to analyze the forming process of aluminized parts in this paper, and the empirical process plan is revised through the results of virtual verification, and on this basis, the stamping process parameters are fine-tuned in combination with a small range of trial and error verification on the production site, so as to realize the small sheet cost of the aluminized outer plate of a light truck door, that is, the parts that can be used for product test and evaluation are trial-produced. With the application of such methods in the trial production process of door outer panels, it provides a reference experience for the feasibility demonstration of various types of aluminized shallow drawing parts.

Key words: Aluminum door outer panel; Truck lightweight; CAE forming analysis; Trial production

摘要： 近年来随着卡车产业的高端化转型，市场对卡车轻量化的要求已成为重要技术突破方 向之一，在不改变原车身制造体系前提下的铝合金材料替代研究成为热点。如何能更有效控 制试制验证成本，尽可能压缩模具前期投入费用和工艺验证周期，是轻量化项目重点关心的 问题。文章采用计算机辅助工程（CAE）成形分析技术对铝化件成形过程进行分析，通过虚 拟验证的结果修订经验性工艺方案，在此基础上结合生产现场小范围试错校验微调冲压过程 参数，实现了某轻卡车门铝化外板用很少的板料成本，即试制出可供产品试验评估的制件。 随着此类方法在车门外板试制过程中的应用，为后续各类铝化浅拉延件的试制可行性论证提 供了宝贵的经验。

关键词: 铝化车门外板；卡车轻量化；CAE 成形分析；试制