Study On Stamping Forming Process Of Jaguar Backdoor Frame Aluminum Alloy Trim

Automotive refers to the automobile external decorative or functional components,mainly including bumper,fender,scuff and so on.The aluminum alloy trim of rear door frame studied in this paper belongs to exterior decorative parts.Besides its material is thin,its size and shape are more complex.There are problems,such as cracking and wrinkling in the production.Because it has strict assembly tolerance with doorframe seal components and rear door triangular glass window edge,so the dimension precision and surface quality are required relatively high.Stamping process experienced by qualified trim includ blanking,drawing forming,cutting gap,cutting edge,edge rubbing,flanging,trimming and so on.The final forming quality of the part is the key to drawing process and it also directly determines the follow-up process can produce qualified products or not.Through uniaxial tensile test at room temperature,strain hardening index n,thickness anisotropy coefficient r and other parameters that are used to evaluate the material formability were obtained.The trim inside corner location is easy to crack,so designed forming die ang did stamping test.It is helpful to improve the quality of the formed parts by properly reducing flanging height and selecting plate with high n value.Through analysing the forming process of the trim,make sure it can be drawn at on time.Following the principles that how to determine stamping direction,the clearance between punch and die and the design methods of binder surface,I designed the drawing die.Referring to the literature,the design parameters of other process die were determined and the design sketchs of the main mold part wre made.The initial blank shape and size of the parts are obtained by using the function of BSE module of DYNAFORM software,and the shape and size of the blank were improved after the simulation of the drawing forming.Finally,obtained forming parts of good quality.Studied the influence of drawbead resistance,stamping speed,friction coefficient and die fillet on the quality of drawing parts.Optimizing and combining the above parameters by the method of orthogonal test solved the cracking defect locatied trim’s inside corner in flanging.The forming safety margin has been improved aftermading some optimization of the inner side r angle of the trim’s corner,slope angle.Used the optimized forming process parameters and the improved part model to do test verification and obtained stamping parts with good quality.Safety margin accorded with the requirement of industrial production,and the experimental results were in good agreement with the results of finite element simulation.