Aluminum Alloy Auto Body Enclosure Panel Stamping Process Design And Process Parameters Robust Optimization

Nowadays, the energy and environmental crisis is picking up, the auto industry isbound to develop in the direction of energy conservation and environmentalprotection. The use of lightweight alloy material is one of the most important ways toachieve the goal. Due to its light weight， high specific strength， high thermalconductivity and excellent corrosion resistance, aluminum alloy sheet is becomingthe most popular lightweight materials for the automobile manufacturers. However，the disparity on the crystal structure making the traditional steel panel forming theorycannot be directly applied in aluminum alloy panel stamping process, and traditionaldesign methods rely on experience and repeated trial mold, repair mold process, oftenmake the product development cost is high, the market cycle is long. We need to findsuitable stamping process design method for aluminum alloy sheet.With the rapid development of finite element analysis，statistics and optimizationtheory, combine them to do sheet metal stamping forming process numericalsimulation and optimization design, can be able to predict the possible defects andfind the optimal parameter combination, which will improve the efficiency andquality of product design. As the parameters in the stamping process are tend to havea certain degree of volatility, we need to take their impacts into account. This papertries to explore suitable stamping process design method and process parameters’robust optimization method for aluminum alloy sheet considering the influence ofuncertainty factors. We carried out the following major works:Firstly, introduced the automotive aluminum alloy sheet research and usingstatus quo，points out the shortages in the existing research， and proposed theresearch goal and research content of this article.Secondly，introduced the robust optimization design theory,6Sigma robustoptimization design method and response surface method, which lays the foundationof the robust optimization design method of aluminum alloy sheet forming.Thirdly, introduced theory of the numerical simulation of sheet metal stampingforming, analyzed the relevant factors influencing aluminum alloy sheet stampingforming quality and defined the quality evaluation criteria, combined with the robustoptimization method, established a6sigma robust optimization design method ofaluminum alloy sheet stamping forming process based on response surface. Then，taking a car’s6016_T4P aluminum alloy outdoor plate stamping formingprocess design as an example, using AUTOFORM software to simulate the process.The simulated result will be the foundation of subsequent robust optimization design.Finally，on the basis of the above work, using6Sigma robust optimizationdesign method to optimize the6016_T4P aluminum alloy outdoor plate’s processparameters. During the optimizing process， considering fluctuation of materialparameters， setting the optimize objective is minimize reduction ratio, and norupture，wrinkle，insufficient drawing are the constraint function，the design variablesare BHF, DB1-4, DB2, DB3etc. By comparison the analysis results and simulationverification of deterministic optimization and robustness optimization，proving thatthe robust optimization can not only guarantee the forming quality of the products，but also improve the design reliability at the same time.