为提高多工位级进冲压成形质量，降低模具制造成本，对某汽车车门导轨结构件冲压过程中所涉及的压弯－拉深、修边、整形、翻边等成形工序和回弹卸载进行了有限元数值模拟，预测了成形过程中可能出现的载体畸变、拉深破裂、翻边破裂和回弹等成形缺陷，分析了缺陷产生的原因，并提出了相应的解决或控制措施，由此重新建模，获得了理想的模拟结果． 基于数值模拟结果进行了多工位级进冲压试验，成功冲制出了一模两件成形质量合格的某车门导轨结构件，该模能满足大批量生产要求．

In order to improve the forming quality of multi-position progressive stamping and reduce the cost of diemanufacturing,the stamping process of the structural part used for car door rail is simulated in terms of bendingdrawing,trimming,shaping and flanging as well as of springback after unloading.Then,such forming defects ascarrier distortion,cracks in the process of deep drawing,flanging and springback are predicted and analyses on whythose defects occur are performed.Moreover,corresponding measures for solutions to or control of such problemsare raised,which aid to rebuild the finite element model,and thus ideal simulation results are made.Finally,aprogressive stamping trial is carried out according to the simulation results,and a set of qualified left-right car doorrails is successfully produced by means of double-die symmetrical pressing method.In addition,the manufacturedprogressive die is able to meet the requirement of mass production.