Automotive Stamping Process Numerical Simulation And Optimization

At present, automobile manufacturing is one of the pillar industries ofChina's economy. Automobile panels are the main parts of cars, and thedevelopment and production cycle of the automobile panels will directly restrictthe replacement cycle of the automobiles. Traditional R&D and productionmethods mainly depend on the experience of the technical staff and obtainreasonable parameters by stamping and adjusting the mold several times beforeproduction. Because of the structure complexity of the automobile panels, thewhole time of production and commissioning process will be long, the cost ofthis process will be high and quality stability of the products can not beguaranteed either.With the development of computer technology and the finite elementtheory continue to become mature, various kinds of CAE software are developedand used in the actual production. These can not only forecast some possibledefects of the tensile parts under a certain process but also improve the formingprocess and the structure of the mold according to the simulation results. In thisway the production cycle and the testing cycle of the mold can be shortened.The production costs are reduced and the quality stability of the panels is greatlyimproved at the same time.By use of the finite element simulation software—Dynaform,this articlefirstly does a simulation research of a typical simple stamping parts—abox-shaped part and discusses the forming process of the general stamping parts.On this basis, the author does the simulation research to the complicatedstamping parts—the outer panel of the trunk and optimizes the relative theparameters. The main influential parameters are identified and the influentialdegree of these parameters is also obtained. Combining with the multi-objectivefunction analysis Y and regression analysis method, this article further discussesthe impact law of the two main influential parameters and a group of bestparameters are obtained. The main content of this article are as follows:(1) By use of the finite element simulation software—Dynaform, theforming process of box-shaped part are simulated to study the influence of various process parameters to the forming result in the stamping process. Theinfluence of the blank holder force, fillet radius, friction coefficient anddrawbead resistance to the forming result are mainly analyzed. In the end areasonable range of options is obtained according to the box-shaped part. Thesehave provided theoretical basis and references for the study of the complicatedstamping parts in future.(2) Finite element modeling of out panel of the trunk. By use of the finiteelement simulation software Dynaform, the author elaborates the whole processof the finite element modeling of out panel of the trunk. Generation of thethree-dimensional model of parts, addendum, drawing grid model as well as theadding of the binder surface are included in the process. Various processparameters are determined after preliminary discussions.(3) Numerical simulation and optimization of out panel of the trunk. Basedon the molding that has been established, the author optimized the parameters ofthe blank holder force, friction coefficient, clearances between and drawbeaddepth. The influence degree of the four parameters to the forming result aresorted. Combining with the regression analysis method, this article furtherdiscusses the impact law of the two main influential parameters. Based on theanalyzing of the process plan after optimization, the multi-objective analysisfunction is proposed in order to further optimize the process and gain a bestgroup of parameters. In the end, this article compare and analysis the parameterswith the actual stampings and find it is highly consistent with the actualparameters.