Research On Stamping Forming Numerical Simulation For Side Beam Internal Plate Cover Of Car

With the rapid development of automotive industry in our country, the renewed rate of automotive types has increased continually. The design and manufacture of automobile panels are the important aspects which decide whether corporations can exploit the needed production to occupy market with the fastest rate and the lowest cost or not. The very short life cycle in addition to the quite long time for designing and manufacturing of automobile panels have made the fact that the traditional methods can not satisfy the demand of production development. The forming of automobile panels has become the bottleneck of automotive production's exploitation, as well as the main factor which restricts the development of automotive industry. Therefore, during the exploiting and producing of automobiles, the using of CAD/CAM technique is the inexorable trend for developing automotive industry in our country. Through stamping forming numerical simulation technique, the engineer testing number of new productions can be decreased so as to short the cycle of exploitation process. The exploitation cost of new productions decreases, which brings enormous economic benefit for corporations.Based on the study and summing-up of present domestic and overseas research productions, the fact application of sheet forming numerical simulation was discussed in this paper. The development of finite element analysis was generalized, as well as the unit types of finite element, yield guideline, relationship between stress and strain, and materials model in drawing simulation. The treatments for contact and friction problems were discussed, at the same time, the forming characteristics of panels the factors of normal flaw and their judgments were also induced. Based on them, the key technology and experimental method of automobiles panel numerical simulation was advanced. The paper also indicated the normal process of simulation, geometrical model, mesh division in front treatment course according to the characteristics of car panels.The paper emphasizes studying the industrialized application of sheet forming numerical simulation and also analyzing the formability of automobile panels. The side beam internal plate cover of car was taken as the subject investigated, meanwhile, the CATIA software produced by ETA Corporation was chosen for the three-dimensional moulding floor. Through leading-in the IGES files into DYNAFORM software, based on the real work conditions, the numerical simulations were carried out. In this paper, the mechanisms for flaws such as fracture, wrinkle and rebound which occurred in forming process frequently were discussed, and the effects of blank dimension, pressure-pad-force, braking bead and materials parameters on sheet forming process were also investigated.Finally, the processing parameters for corresponding productions were optimized, which offered the necessary information and technology support for die design and production modification. The results are as following:1. The development history and research present state of sheet forming numerical simulation are generalized, meanwhile the characteristics and applicability of dynamic and static display algorithm are also compared. The viewpoints that dynamic display algorithm is always used for sheet forming simulation course while the static display algorithm is used for the rebound course are considered.2. The structure and forming characteristics of automobile panels are analyzed, as well as the effects of materials and properties on forming. Based on them, the general procedures of finite element analysis for sheet forming using DYNAFORM software are summarized.3. The drawing direction of side beam internal plate cover of car is determined. The technology addition and the finite element model are built respectively. The results indicate that reducing the blank size is better with the condition of forming completely, and the appropriate shape and size of blank are obtained by calculations.4. The pressure-pad-force of 600 KN, 650 KN, 700 KN, 800 KN and the braking bead height of 4 mm, 4.5 mm, 5.0 mm are simulated, and the preliminary simulation version is found out. The pressure-pad-force, the braking bead height and the arrangement of braking bead are adjusted according to the forming situation at different place of sheets. Through multiple optimizations, the pressure-pad-force of 700 KN and the braking bead height of 5 mm are chosen. The fracture and wrinkle are avoided by the method of removing four quarter braking bead. Finally, the technology parameters are determined, which can make the forming results better.5. The main factors which affect the rebound simulation accuracy are discussed. The unloading rebound and side cut rebound of the formed components are analyzed. The maximal rebound amount is smaller than 2 mm, which offers a guiding value for die design.Using numerical simulation technology for automobile panel forming is benefit to forecast the fluidity of metals, stress and strain, possible flaws and other failure formats, which makes proofs for optimizing technology parameters and die structures. The researches are significant for keeping work quantity, reducing materials waste, shortening the product development cycle, and reducing the manufacturing cost.