Flanging And Springback Simulation System Research For Automotive Panel Based On NX

The shapes of automobile sheet metal parts are generally complex, and it needs drawing, trimming, flanging and other multi-channel stamping forming processes. Flanging process usually acts as final forming process, and springback is always accompanied by rebound flanging process, and ultimately affects the quality of the assembly and welding of parts. How to reduce the impact on the quality of the parts has been always annoying the designer. In the actual process and die design process of flanging forming, designers mostly rely on their own experience, and to ensure the quality of flanging forming part back through repeated testing, which greatly wastes design cost and design time. To assist designers to improve design efficiency and cost savings, and improve the flanging springback prediction accuracy, developed a flanging and springback simulation of CAD/CAE integration system becomes imperative.This research is supported by the National NC Specific Project “Stamping die development of whole body side, fender and interior of new environmentally friendly materials in C-class car”(No.2009ZX04013-031). The purpose is to develop the flanging simulation system FFSW for automotive panel based on NX platform using second development tools UG OPEN C. The system can simulate the real flanging forming process, forecast the springback, cracking and wrinkling. It also can help the designers in flanging process and mold design, improves design efficiency and cost saving.Firstly, The paper has analyzed the developing tools UG OPEN C, flanging process and flanging springback in detail. In view of the needs analysis of system development, determines the overall framework structure of system, summarizes the user interface and functions of FFSW system.Secondly, The paper focus on the key technology of the FFSW system. By making use of the technology of mold automatic surface discrete facet body, it realizes mold assembly of flanging simulation in NX modeling environment, and avoids slowing saved and updated and showing the complex component. With the discrete facet body, flanging simulation was set up and the problems of assembly and interference for flanging were found before flanging simulation. By using freedom springback technology, it improves the forecast accuracy of flanging springback, realizes the effect control of flanging springback. With the direct restart technology, ensures in the wrong process definition to reduce the simulation time of process redefinition and greatly improve efficiency of the simulation.Finally, two particular examples for auto parts are given to do the flanging forming and springback simulation by using FAW5.0 full process simulation process and the flanging and springback simulation system for automotive panel. By contrast forming simulation results and experimental results illustrate the effectiveness and accuracy of the system.