Automotive Panel Flanging Process Of Cae Simulation Modeling And Applied Research

In practice, the predication of the trimming line, which is the reference of trim die design, was decided by trial-and-error procedures. It is not only time-consuming but also expensive. Based on the FEA, this paper discusses the simulation of the flanging process of large and complex sheet metal parts. Applying the optimum blank theory, the method predicating the location of the trimming line is proposed. Key issues discussed in the paper include the following:(1) Geometry modeling - it is the premise of the simulation. The quality of the model affects the FEM mesh generation. The main issue is the disposal of important small features such as the blend between two faces. By use of the Unigraphics, the author built the geometry model of the complex part and discussed the key technology of modeling.(2) FEM modeling -the main issue is how to mesh the part and control the mesh quality. Concerned with this aspect, some advices in flanging simulation was put forward, such as how to dominate the tendency of the mesh near the flanging line; how to unite the different mesh to form the mould mesh; how to reasonably assign the mesh size and optimize the parameter of the simulation and the mould dimension. FEM modeling of the die, punch and the binder is discussed for a typical industrial application.(3) Method for the determination of trimming line - bring forward the method predicating the location of the trimming line based on the simulation. By iterative simulation calculating, relatively good trimming line can be obtained and an actual flanging experiment is carried out in order to verify the correctness of the method.The application proves that the method proposed in this paper could solve the problem well. The method can efficiently reduce the time and the cost of the development of the new product. It also enriches the application of CAE in the sheet metal forming process.