Stamping Forming And Process Design Of Aluminium Alloy Automotive Covering Parts

In the past years,with the rapidly developmen t of the automotive industry,it has become one of the pillar economic industries in China.With the increasingly serious energy crisis and environmental problems,energy-saving and emission-reduction have becoming the focus of the world.Automotive lightweighting has becoming the important method to reduce energy consumption of vehicle in the automotive companies.Th ere are three methods of automotive lightweighting: materials,structure and process lightweighting.The use of lightweight materials are one of the main methods of lightweighting.T he aluminum alloy,which has superior properties of high strength,low density,ease of processing,has attracted many automobile enterprise 's attention.The application of aluminum alloy in the car body has gotten a good opportunity,meanwhile it has brought great challenge to traditional stamping technology.In this thesis,Auto Form has been used to investigate stamping forming and process design of aluminum alloy automotive covering parts.Firstly,the aluminum alloy materials has been discussed b ased on theory of finite element numerical,including the elastic-plastic constitutive model and the yield criterion,element model,contact algorithm and static implicit algorithm and one step-forming method,which provided theoretical basis for the subsequent research.Secondly,combining to the product quality control points,according to the process plan of the outside steel plate door,designing of the whole process and scheme of Aluminum Alloy outer door panel has bee n performed,which divides into four steps: OP10 drawing process,OP20 cutting/punching,OP30 separation/punching,OP40 flanging/plastic.Thirdly,with the help of finite element analysis software Auto Form,numerical simulation and detail process design of the drawing process of the automobile's door has been performed,under differential conditions,including Tipping,addendum,drawing beads,blank holder force and friction coefficient.And the optimization for drawing beads,blank holder force and friction coefficient have been finished.The effect of the adjustment of the blank holder force and friction coefficient on the plastic deformation of the material is studied in detail,which provides a theoretical reference for the subsequent adjustment of the s pringback of the parts.And CAE simulation analysis report have been obtained at last.Finally,the designing of the trimming,punching,flanging and separation process of the aluminum alloy outer door panel have been conducted.In the meantime,the springback simulation analysis has been carried out on the automotive door outer with aluminum alloy,and the scheme of springback control through discussing the springback factors is proposed,which providing great technical support for mold development and tr ial manufacture of parts subsequently.