Study On The Box Filler Stamping With Numerical Simulation And Experiment

The drawn component of the car box filler is typical non axis-symmetric deep drawn curved part. Its forming part is belongs to deep drawn. Its dimension in height is greater than that in width. The material deforming distribution on flange is severely uneven. And its flowing feature is not the same as straight-wall deep cup. The process of this kind of parts is still designed by analogy, based on qualitative analysis, physical simulation and experimental verification, theory analysis is lagged severely. And the experience knowledge from production has defect which is not obvious and not systemic. Direct dynamic results can be obtained by simulation. The results can guide actual production, reduce waste rate and boost die life. So study on this kind of parts by numerical simulation has both theoretic and practical value. It can detailedly analysis the whole process of sheet metal forming, provide the detailed information about the material transmutation mechanics and forecast the question or defeat may appears that we adopt the numerical simulation. It also largely decrease adjusting time and experiment cost and gain a lot of information that can't obtain in the experiment. The study is to perform plastic finite element method for the whole process of car box filler forming and forecast the question or defect may appears, through using the advanced software DYNAFORM of American ETA, Inc. then the technology and die parameters are optimized, which provide theory basis for forming, equipment and die design of box filler. On this basis, equipment and die are manufactured. The experiment results fit mutually with the simulation data, and finally the new production technology of optimized box filler forming is identified. The time of adjusting tool reduce more than 50 percents, the amount of wall thickness difference of box filler are reached less then 5 percents. The shape and dimension fit mutually with the drawing of product. By the method of the numerical simulation, the effect of the technical parameter in sheet metal forming process is researched. Through the analysis of the result of the numerical simulation, the conclusion can be found. In the stated condition, the change of the material mechanical parameter will affect the performance of sheet metal forming. But we can not blindly seek the high capability of the material. When the dimension of the mold has been confirmed, the connection of the selection of mold geometrical parameter and the performance of the sheet metal forming is very tight, and the good selection of mold geometrical parameter can decrease the forming detect of the sheet metal forming process. In this paper, chapter 1 is the introduction of study target, content, method and domestic and international present conditions. In chapter 2 introduction forming design of box filler and emphasize the design method of the key process factors. In chapter 3 brief analysis for the forming characteristics, and bring forward the defeat mode and the measure. In chapter 4 the sheet metal forming finite element method is demonstrated in detail combining the factual characteristics of the box filler metal forming process. In chapter 5 introduction how to select finite element software, the basis process of using software and how to improve analysis efficiency. In chapter 6 analysis for the effect of the major material mechanical parameter and tool technical parameter, evaluation the importance of effect and confirm the technical parameter. In chapter 7 where pointed that the 2 times forming produce the smaller wrinkle and its smaller extension by comparing with the 1 time forming process. Also pointed that the normal strain decrease, the max stress decreases, material flow even, and the formability is improved to a greater degree by adopting the 2 times forming process. But the crack appears however, so we should adjust the process parameter. In chapter 8 where the wrinkle and crack of box filler is studied in detail, and bring forward the measure avoiding these defects . In chapter 10 where the experimental process of box filler forming is introduced in detail, the main problem in experiment is analyzed, and the corresponding countermeasure is put forwarded, also the experimental results is compared and analyzed with the simulation data.