Optimum Design And Algorithm Study Of Auto Body Parts' Flanging Trimming Line

Auto body parts mainly include covers of the engine and chassis, parts of cab and body, such as mudguard, roof, car door panel, engine cover, radiator cover and trunk cover. Comparing with general stamping parts, there are some especial characters of auto body parts, such as little thickness, complex shape, complex surface, higher connecting requirements between surfaces, large structure size, high surface quality requirements and rigidity. So, it's difficult for auto body parts in designing stamping process, designing and manufacturing die.Comparing with general stamping parts, the stamping process of auto body parts is more complex. There are more problems that need to be considered. The stamping processes of auto body parts generally include 4 to 6 work procedures, and what's the most include nearly 10 work procedures. A qualified auto body part is usually completed through blanking, drawing, cutting edge (or punching), flanging (or punching), punching and other processes. The deep drawing, trimming and flanging is the most basic three processes. For flanging of auto body part, the most important factor that impact flanging formability and forming accuracy is the rationality of cutting edges. So the key of flanging forming is how to quickly and accurately prefigure the trimming line after deep drawing. In the production of auto body parts, there is not yet a quick and effective method to prefigure the trimming line. However trial and error method is used mostly. In order to obtain the required height and shape of flanging, we have to repeatedly correct the size and shape of trimming die, which not only results in great waste of materials and manpower, but also adds the entire time of manufacturing and testing die, increasing the cost of manufacturing tools and holding up the development progress of new product.How to prefigure the size and shape of the trimming line, so that there is a perfect flange after the flanging process, is very important for reducing die manufacturing cycle and the product cost. But for the entire die industry, it is also a major problem needed to be solved.Based on Microsoft.net, a process of predicting optimal trimming line of complex flanging was developed. The researching method was numerical methods. The finite element simulation method was used into the traditional successive approximation method. The method of modifying blank shape by hand in the past was replaced by the finite element software.An iterative algorithm that prefigures complex flanging trimming line based on error correction was proposed. Based on the finite element simulation of LS-DYNA, according to the error values of simulation results and the target curve, the blank is corrected. After one or two iterations, an exact trimming line would be obtained. The program could automatically call LS-DYNA solver, which greatly increased the efficiency of the trimming line optimization. A flanging simulation study proved that the method was effective.