Numerical Simulation of Stamping Forming of Automobile Cover
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Abstract:
The main defect of the inner-hood is break, which was obtained by the numerical simulation of it’s forming process. The main impacted parameters of sheet metal forming process are corner radius of die, friction coefficient, clearance between punch and die and the height of drawbead. The maximum impact of the break of forming factors was drawbead high, followed by the die gap, die edge and the friction coefficient which were obtained by the four factors orthogonal optimized simulation. The comparison between the results of numerical simulation and actual operation proved the accuracy of the numerical simulation.Keywords:
Stamping
In sheet metal fabrication using an NCT (numerically controlled turret punch press) machine, automatic tool selection is a major problem to be solved to improve its production performance. However, this operation has been done either manually or semi-automatically by human experts. In this paper, we have introduced the shape-index-set to handle the shape of sheet metal parts and developed an algorithm through which one can find the successive matching curves between two curve lists, one from the punching tool and the other from the boundaries of the sheet metal part. The algorithm is used to select the tools automatically to punch out the boundaries of sheet metal parts. Several experiments are presented to prove the successful tool selection.
Stamping
Turret
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Low forming accuracy is an important defect of sheet metal incremental forming process. Aiming at the evaluation of incremental forming accuracy, an evaluation method based on displacement error is proposed, i.e. the forming accuracy is measured by determining the deformation displacement along the measuring direction. Forming accuracy of a set of cone type formed parts is studied by using the displacement error method, and the important influencing factors of the forming accuracy are springback of sheet metal and stiffness of forming tool system, were advanced in this investigation. During the forming process, constant forming angle causes constant springback, varied forming angle causes varied springback, and there is a nonlinear relationship between the forming angle and springback. Based on this, forming accuray improvement methods of the formed parts are indicated: (1) compensating the error size caused by the springback of sheet metal and insufficient stiffness of the forming tool system, (2) increasing the stiffness of the forming tool system. Experiments prove that both (1) and (2) can greatly improve the incremental forming accuracy of parts.
Incremental sheet forming
Metal forming
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In recent years, enormous progress has been made in the industrial use of digital tools with the aim to simulate the formability of sheet metal processes. This is especially true for the automotive industry, in order to verify and validate stamping feasibility. Indeed cost and quality targets in industrial sheet metal forming processes, correct formability prediction in a very early project stage has become a crucial factor. This is the reason for the wide application of FLC for the purpose of measuring and predicting limit strains, thus to study the influence of various materials or process parameters on strain paths. This article attempts to give a brief introduction to the subject of stamping sheet metal forming and describe some of the forming defects that can occur, thus the failure criterion is presented and applied to a deep drawn part via the Autoform simulator.
Stamping
Deep drawing
Forming limit diagram
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This paper presents a discrete multi-point forming process to deal with the problem occrring in the large-scale sheet metal stamping and introduces the structures of the mold and stamping bars applied in this process. Compared with the existing multi-point forming processes,such as poles flexible forming and misaligned stamping processes with swivel square press heads,the discrete multi-point forming process shows its advantages in the process of the large-scale sheet metal stamping.
Stamping
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This paper introduced the sheet metal layered incremental forming process. Since the technology of the sheet metal layered incremental forming process is relatively complicated,and various parameters and process mark are difficult to choose by the experimental methods it is the key factor for sheet metal digital forming process to choose reasonable technology parameters to get ideal process workpiece.The sheet metal layered forming process is a multi\|stage forming process,the paper introduced FEM simulation project of sheet metal layered forming process.
Incremental sheet forming
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Wrinkling often occur in the sheet metal forming processes,it is the result of the compression buckling.Multi-point forming and technique was explored that can improve the sheet stability and reduce the wrinkling of the sheet metal forming processes.Sheet metal is restricted by the elastic pressing force putting on the upper and lower surfaces of sheet in stamping.Based on the technique,reconfigurable poles flexible die was developed.The die can be used to implement the stamping processes of multi-point pressing and forming.The results of tests indicated that the die can be reconfigured quickly and suppress the wrinkling of sheet.Multi-point pressing and forming technology provides a practical and effective way for the curved sheet metal forming.It is especially applied to form the sheet metal parts with middle-small batch.
Stamping
Multi point
Single point
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This paper attempts to optimize the forming quality of sheet metal by drawing the formability region diagram based on the forming limit diagram of sheet metal, which provides a method for rapid adjustment of stamping process parameters in production. Fristly, the strain of sheet metal forming limit was quantized to obtained the standard of sheet metal forming quality. Secondly, the formability region diagram of sheet metal is got by using the method of orthogonal test, finite element numerical simulation and BP neural network. Finally, taking an automotive rear end panel reinforcement as an example, the stamping test was carried out by selecting the process parameters corresponding to different points in the stamping formability region diagram, and the test results were consistent with the results reflected in the formability region diagram. This paper provides a method to improve the quality of sheet metal forming and quickly optimize the stamping process parameters, which has important engineering application value.
Forming limit diagram
Stamping
Deep drawing
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Springback is an inevitably phenomenon in sheet metal forming processes and directly affects the precision and the final shape of stamping parts.Different scholars proposed different methods to prediction and optimization the springback and some of them were summarized in the paper.Various methods to reduce or eliminate springback such as material selection,structural design,processes design,die gap and die structures optimization were proposed.
Stamping
Tola
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The stamping formation modes of sheet metal,the relationship of the modes' conversion rule and the classification of the formability based on the different fracture's unsteady patterns were described.The simulating formability test methods such as the approximating method of simplifying non-cylindrical project to partial cylinder,the simulating-profiling method for the deformation and shape of projects,and the method of reducing project's dimension scale were proposed.There were three basic modes for the designing the simulating formability tests.Furthermore,various kinds of current test methods of sheet metal formability were analyzed,which could be used as the basis of selecting and applying test methods for revising GB/T 15825《Sheet Metal Formability and Test Methods 》.
Stamping
Forming limit diagram
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Simulation of sheet metal forming is one of the major applications of LS-DYNA. Today, a majority of the forming industry is using Finite Element models to design the stamping dies in order to preve ...
Stamping
Metal forming
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