| As one of main components of the car, auto cover has the characteristics of complicatedstructure and high surface quality, which make it difficult to grasp the principle of deformationand easy to initial forming defects such as crack, wrinkle or springback in the process ofstamping forming.With the development of technology, the pursuit for high-quality products notonly greatly increases the difficulties of quality controlling and mold developing, but alsobecomes the key point to improve the core competitiveness of auto enterprises. Introducing CAEtechnology into the automotive field, can not only simulate the forming process, but also predictthe forming results, which has important significance for improving the level of forming processand lower production costs.The front top light installation sheet as the research object in this paper, analyzed itsformability and finished the numerical simulation of the forming process based on the AutoFormsoftware. The simulation results can help take effective measures to control the forming defectsand springback problems occurred during the forming process, which is very important toprovide guidance for the actual production of stamping parts and meet the high-qualityrequirements of products.The main work of this paper is given as follows:1. It summarized the characteristics and quality requirements of the auto cover, and brieflyanalyzed the defects that may arise during the forming process of sheet and control methods, aswell as the theoretical basis of numerical simulation of stamping forming. What’s more it alsopresented a brief explanation for AutoForm software.2.Researched the formability of the front top light installation sheet. Inconsistencies ofdrawing depth in the Parts will lead to uneven sheet flow at different locations, which may resultin excessive thinning in the sidewall. Small rounded transition and uneven distribution of stresscan lead to forming defects such as excessive thinning or even crack, etc. At the bottom of thebending part, it is easy to cause the springback problem. Taken St14as research material, itsimulated the forming process of the front top light installation sheet and discussed the effect ofBHF, drawbeads, die fillet, friction coefficient, die clearance and other process parameters uponthe formability, which was based on the metrics of thinning rate, wrinkling rate and springback angle size.3. The numerical simulation of the front top light installation sheet based on the AutoFormsoftware. The processing addendum was determined according to the structural characteristicsand formability of this Part. After establishing the finite element model, it simulated each step ofthe processing and put forward a reasonable forming solution through the adjustment andoptimization of processing parameters.4. Springback simulation of each processing step based on AutoForm software. Analyzingthe simulation results, it showed that the product overall had a small springback.It also simulatedand analyzed this Part without controlled factors based on AutoForm software.According to the structural characteristics of the front top light installation sheet, it predictsthe forming defects that may arise using AutoForm software and designs a reasonable stampingproject by improving the type surface structure via addendum and optimizing the processparameters. To control the forming quality for meeting the criterion and guiding the actualproduction, each step of the forming process was analyzed and its springback was alsosimulated. |
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