Stamping Process Design And Springback Optimization For The Pickup B-pillar Inner Panel Upper Reinforced Panel

High-strength steel has been widely applied in the automotive industry in order to satisfy the low-power, light-weight and high-security developing trends in automobile manufacturing industry. The majority of vehicle parts are covered in complex shapes and the strength and plasticity of high strength steels contradict each other which have thus brought various problems to stamping of covers, among which the control of springback is the most prominent problem which has increased the difficulty of dies designing and manufacturing. With the rapid development of computer technology as well as its wide application, using software such as Autoform to simulate the process of forming sheet to analyze results and control the generation of defects by optimizing forming process parameters and ensure the rationality of product design which can not only shorten the developing cycle but also lower the producing cost.This paper mainly selects pickup B-pillar inner panel upper reinforced panel as the research object from the following three aspects.Firstly, the process of the inner panel upper reinforced sheet of pickup B-pillar within B410LA/JSC590 R high strength low alloy steel was analyzed and two forming methods were designed. Plan one designed the part surface flange in the binder while in Plan two it was designed in the punch. Using Autoform to carry out numerical simulation analysis on these two formed process programs has successfully predicted the wrinkle, crack, forming inadequate and other defects. Through making comprehensive comparison, plan two was superior plan one. At the same time, the simulation result was testified by the production and thus high-quality parts can be produced.Secondly, the springback was chosen as an index and the major influencing points of springback(including blank holding force, punching speed, friction coefficient, and sheet thickness) were selected as the factors of the orthogonal experimental design. Each factor has three standards. At last, the combination of process parameters which can control the maximum springback angle to a minimum was acquired. Besides, according to the analysis of orthogonal experiment of range and variance, the blank holding force and punching speed are the major influential factors of springback. In addition, corresponding verification was made on theoptimal combination of statistical analysis which shows that the maximum springback angle is2.15° which is much better than the stimulating results of any combination of parameter on the orthogonal sheet. The quality of sheet forming can be guaranteed which proves that the optimized plan of the orthogonal experiments is feasible.Finally, based on orthogonal experiment design, by establishing a radial basis function agent model of sheet forming and using fmincon function in optimization toolbox of Matlab to optimize the solutions, the predictive value of springback was obtained which is 2.13°. Through making numerical simulation on the optimized parameters, it was found that the error between the value of simulation and prediction was 0.94% which proved the quality of sheet forming has also been guaranteed and the feasibility of the proposed approach has thus been verified.