Optimizing The Design Of Automobile Die With CAE Technology

Because of the automobile cover's high accuracy requirement and volume production, all of the automotive industries carry on the production by stamping. The Sheet metal forming is a plastic deformation process with large deflection and large deformation. It involves the plastic flow and plastic enhance, which under the complex stress state during the stretching and bending , as well as the cause of wrinkles, cracks and springback. In addition, the stamping is also a complex multi-body contacting mechanics analysis. Therefore, in terms of sheet metal forming, it is difficult to anticipate the result by the experience alone, and the accuracy of die design is also difficult to evaluate, so the problem only can be exposed after die machined, which caused a great deal of debugging problems and even lead to die scrapped.The application of simulation can detect problems as early as possible to improve the die design, thus it greatly shorten the debugging time and reduce costs. The use of numerical simulation can predict and eliminate the wrinkles and cracks. Years of production experience testify that many CAE software has very high accuracy comparing to the real results, such as AUTOFORM, DYNAFORM, PAM-STAMP, have been widely used .In this paper, numerical simulations to some different parts have been carried on by three above CAE software. According to the comparison result, each software simulation precision and the good or bad points are analyzed. In view of the different parts' formed characteristic, I distinguish the influence to the forming simulation precision among the different parameter setting. Regarding the more or less tolerance in springback of the present sheet forming CAE software's computed results, In this paper, many parts' actual springback and the numerical simulation result are compared. According to the characteristic of springback I try to find the reason why tolerances exist, which can be helped to improve the simulation precision. In addition,a method to compensate the springback by the CAE technology has been introduced in this paper.