System Development Of Flanging And Motion Simulation For Automotive Panel Based On CATIA

Flanging is one of the very important steps in automotive panel stamping process,almost all automotive panels have flanging process, some complex parts even exist threeor four flanging processes. And it is usually formed as the finishing process, the formingquality impacts directly on the precision and appearance of the products, and assembly,welding quality. In actual flanging process and flanging die design, craft workers oftenrely on experience to ensure the flanging quality through trial, which not only wastes a lotof manpower and resources, and makes design cycle longer and efficiency lower. In orderto assist designers designing rational flanging process and mold, and improving designefficiency, it is necessary to develop a oriented structure flanging simulation system whichachieves seamless integration of CAD/CAE.The thesis is supported by numerical control equipment state major R&D projects (No.2009ZX04013-031), and aims at developing the flanging simulation system FMSS forautomotive panel based on CATIA platform using second development tools CATIA-CAA.Based on dynamic explicit algorithm, System can simulate the real flanging process,forecast wrinkling, cracking and rebound phenomenon after molding, to help companiesmake mold design and verification, which shortens mold design cycle and savesdeveloping costs.The paper has analyzed and summarized the developing tools CAA and flangingprocess basis. And made a detailed needs analysis of the system, settled the overallarchitecture of the system, At last, settled the functional interface of the system andimplementation process through the system flow.The paper has introduced the key technology of the CATIA-FMSS in detail. And thissystem introduced the idea of the mold structure travel diagram into flanging simulation,and put forward flanging simulation travel diagram. The flanging simulation traveldiagram can truly reflect the moving sequence among actual flanging blokes, upperpadand lowerpad, the case of flanging blokes cross-cutting, effects on moving sequence thatpressure makes on upperpad, lowerpad and flanging blocks. It made motion simulation by the way of animation based on the Rep to check interference of tools moving, whichneither undermined the model design structure, but also to ensure smooth playback oflarge model animation. It also combined the basic idea of parametric design, used theCATIA user-defined features update mechanism, achieved the CAD/CAE synchronousupdating and integration with CATIA, which avoid losing model data and accuracyduring the platform transformation and improved the efficiency of the designers.The actual stamping parts: car fender and car fender lining board are chose in thispaper, and made complete flanging simulation with full process simulation platform inconjunction with this the flanging simulation system developed in this paper. Throughcomparison of simulation and experimental, verifies the accuracy and effectiveness of thesystem, and proves the system meets the basic requirements of the actual flanging process.