Simulation And Process Optimization In Automotive Panel Stamping

Due to limitations of the technique, the lead time and the development cost in the design phase, an acceptable forming solution is not easy to obtain with a large number of trial-and-error runs. Numerical simulation technology, a quickly developing engineering analysis method, has laid a foundation for the automotive of the forming process design. It has been an indispensable tool to speed up the development of automotive.Most of the existing research on automotive panel forming is focused on verifying whether product defects appear. However, comprehensive and systematic work has rarely been done on how to improve the performance figures of automotive panel in the design phase. Optimization of funning process is a very difficulty problem due to design nonlinearity and huge computational cost of numerical simulations. Therefore, there is notable engineering significance and academic value to seek for a numerical simulation based optimization method for automotive panel forming process.In this paper, the non-linear explicit finite element theory is studied systematicly, which include material models, element algorithm and contact handling methods etc. The FE modeling methods of stamping simulation are investigated and a comparatively deep study on the key points of process. And on the basis of them, the forming simulation of large automotive panels is made and results analyzed.1. The non-linear finite element theory for automotive panel forming simulation is systematically expounded and discussed. Three usually used material models for stamping simulation are discussed and studied, and based on the reference of other research papers, the explicit description of Elastic-Plastic Materials for Hill's and Barlat's yield models are established. BT shell element theory and contact handling algorithm are also expounded in this paper.2. The key parameters in the simulation of stamp metal forming are studied, which include die-face, drawbead and blank-holder force.3. introduce the detailed processes of molding to a part of bumper base on DYNAFORM4. A part of bumper on automotive forming simulation is carried out in the way of orthogonal and the results are discussed, moreover, improved measure is put forward.