Automotive Panel Stamping Simulation And Optimization Of Key Technologies And Stamping Quality Control

Combined with the Yangzhou University and Kaming Mould Co.Ltd’s enterprise graduate workstation project "Researches on the Key Technology of Springback Prediction and Control in the Stamping Forming Process of Autobody Panels", the key technologies in stamping simulation of autobody panels(such as stamping direction, binder, addendum, drawbeads) and the main quality problems of sheet forming(such as the crack, wrinkling, springback) were researched, including computer simulation and real stamping experiments. The idea of setting up basic database on stamping defects was proposed and the framework of this database was established initially. Taking the high strength steel beam as research object, the CAD modeling of automotive covering and the CAE analysis process and method were discussed. The mechanism and control method of reducing the springback were researched.The important roles, the establishment mechanism and principles of the stamping direction, binder, addendum and drawbeads were studied by the typical auto panels such as the hood outer panel, the outside door, the sump, etc. A series of simulation experiments on these key technologies are conducted with the CAD software UG and the CAE software AutoForm. Furthermore, the design method of the key technologies in the stamping forming simulation was obtained. It provides guidance for later production and test research.According to the quality requirement of automobile panels, the common quality problems in stamping forming (such as the crack, wrinkling, springback) were studied. Taking the crack at the bottom of automobile rear wheel cover, the wrinkling on the sump binder and the springback of normal U-shaped parts for example, The mechanism, the classification methods and the main control methods of crack, wrinkling and springback are discussed by engineering mechanics. Taking deep cylindrical parts, shallow drawn components, V-shaped and U-shaped parts as research objects, the CAE prediction of crack, wrinkling and springback were made and the main control methods of these problems were discussed in order to avoid the quality problems.By using Group Technology, statistics, Engineering science and the classified coding methods of automotive panels, based on the present situation of stamping industry in our country, the idea of setting up basic database on stamping defects is proposed. The significance and building steps of this database were introduced. The frame was established initially and it can provide the basis for the future research and production of mold.Taking the high strength middle beam used at the left side threshold for example, according to its characteristics, the initial simulation of it was made in the CAE software AutoForm. Then, the design of the key technologies and die face using CAD, the simulation of triming and springback were finished. The simulation results were compared with the actual stamping results. By optimizing the binder, the pressure and the drawbeads, the springback is decreased and its quality is ensured.