Simulation Of Forming Process For The Inner Panel Of Vehicle Real Wheel Cover Based On DYNAFORM

Since the auto industry appeared, auto industry plays an increasingly importantrole in the national economy, it is not only as a sign of the level of national industryand even become a important indicators for measure of a country’s comprehensivestrength. In the automotive industry, auto cover production increasingly receivedattention. Auto cover is the visual expression of car surface appearance, auto coverreflect the most charm of the car, it is also the important manifestation of the pursuitof perfection. So auto cover not only need to meet the required stiffness but also needmeet the requirements of higher quality of the surface. Auto cover plates are generallythin and the shape usually complex, requirements are extremely high in stampingprocess, which requires auto cover mold must meet the requirements of accuracy, andorder to be competitive in the industry, mold development cycle must be shortened.In the traditional auto cover die development process, there are many factorsrestricting the development of mold. The appearance of CAE technology makes theentire mold development cycle has been greatly shortened. Now CAE technology hasbeen widely used in the major automotive panel die manufacturers because CAEtechnology can not only simulation analysis the product parts, can also simulationanalysis the forming process. Based on the above advantages of CAE, sheet metalforming quality can be predicted, which has great significance of reduce productioncosts and improve shaping process performance. So that in the traditional molddevelopment, mold rework because of design errors can be avoided, it savesmanpower and financial resources.This article is mainly by the way of finite Element Simulation forming process ofauto caver to predict the formed defects. By analyzing the effect of processparameters on forming defects selecting the optimal process parameters. we choosethe DYNAFORM software which has a great advantage in this respect. DYNAFORMsoftware chose the combined explicit algorithm and implicit algorithm. In the chosenof shell elements, DYNAFORM software has chosen shell elements, the amount ofcalculation is decreased and the accuracy improved. DYNAFORM software calculate based on the reverse order of forming process, this method is much simpler comparedto the incremental method, and more in line with the deformation characteristics ofsheet metal forming.In the process of finite element simulation, the forming limit diagram can beintuitive reaction forming result. We can according to the analysis of forming limitdiagram to analysis the forming quality. The forming limit diagram of the softwareused herein DYNAFORM is divided into eight sections, there is a safe state, brokenstate, the risk of rupture point, wrinkling regional trends, wrinkling region, severethinning of the area, no deformation zone, so that the forming limit diagram canpredict crack and wrinkling.This article is about the finite Element Simulation for forming process of theinner panel of vehicle real wheel cover based on DYNAFORM. The first step is todetermine the sequentially of forming step, and then read into the mathematical modeland set the addendum、determine stamping direction、define the parameters of formingprocess，the final is calculation and analysis of simulation results. By repeating thesimulation to obtain the optimum parameters.Discuss the effect of different process parameters on the simulation results:(1)By setting different BHF, analysis the BHF impact on crack and wrinkle;(2) Bysetting different drawbeads. analysis the drawbeads impact on crack and wrinkle;(3)By setting different coefficient of friction, analysis the coefficient of friction impacton crack and wrinkle. This paper also analysisn the springback phenomenon...