Studies On Complete Stamping Process Simulation Techniques Of Automobile Panel Forming

The final shape of automobile panels is obtained by series of processes such as drawing, piercing,trimming, flanging, shaping, etc because of complicated shape and plentiful local features ofautomobile panels. The former processing’s influences on the next ones are taken into consideration inthe complete stamping process simulation, which is able to simulate the whole processes ofautomobile panel forming and effectively indicate a springback. Therefore, the complete stampingprocess simulation has important engineering value.Starting with numerical simulation of the single process of sheet metal forming, simulationmethods drawing forming, trimming and piercing, gravity action and springback analysis of sheetmetal are discussed in detail. A detailed research on key technologies of the complete stampingprocess simulation of automobile panel forming is maked. One tools’ positioning method in thecomplete processing is put forward in which positioning tools in pretreatment firstly and thenadjusting tools’ positioning in the solver. The computing algorithm of distance between meshes isdesigned, by which mesh distances between tools or between tool and sheet metal can be calculated.The approximate configuration of sheet metal can be calculated with methods of mesh projection,mesh smoothing and mesh offsetting. Then, tools’ positioning can be obtained in pretreatment basedon the approximate configuration of sheet metal. With the positioning function of the solver, tools’positioning can be adjusted. In this way, the accurate positioning for tools can be realized and theproblem of initial penetration between sheet metal and tool during the complete stamping simulationis solved. One solving precision controlling method for complete stamping processes simulation is putforward. Adaptive meshing, mass scaling, element type, number of integration points of element, etcare set differently. Simulation requirements in different stages can be satisfied by which the solvingprecision is divided into three levers, low, medium and high. Templates are designed according to thetechnology characteristics and simulation requirements of different processes. Complete processestemplates are established based on different part types. Complete stamping processes simulation ofautomobile panels can be realized.With the above technical researches as a basis and the object-oriented technology adopted,complete stamping process simulation software of automobile panel forming, Multi-QuickSetup, isdeveloped, with LS-DYNA as a solving basis. By making use of this software for complete stamping process simulation of representative automobile panel parts such as bending girder and fender’sforming and the feasibility and stability of this software is proved.