Journal of Jilin University(Engineering and Technology Edition) ›› 2019, Vol. 49 ›› Issue (5): 1608-1614.doi: 10.13229/j.cnki.jdxbgxb20180764

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Finite element numerical simulation for automobile front floor forming

Xin LI1(),Yan-peng SUN1,Dan WANG1,Jun-xu CHEN2,Zheng-wei GU1,Hong XU1   

  1. 1. College of Materials Science and Engineering, Jilin University, Changchun 130022, China
    2. FAW Jiefang Automobile Company Limited, Qingdao 266000, China
  • Received:2018-07-20 Online:2019-09-01 Published:2019-09-11

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Abstract:

Taking the front floor of a car as an example, the finite element software Autoform was used for numerical simulation analysis of forming process. The defects such as splitting, wrinkling, and failure during the forming process of the sheet metal were predicted through simulation analysis. By adjusting the size of the blank holder force, the drawbead parameters, the offset between the punch and the die, and the friction coefficient, the simulation results were optimized to obtain a set of the most suitable parameters for actual production process. After setting the variable strength double drawbeads, the optimum conditions for the process parameters are: blank holder force is 650 kN, forming force is 5200 kN, the offset between punch and die is 0.8 mm and the friction coefficient is 0.15. Based on the simulation results, a forming experiment was carried out and a qualified forming part was obtained, which effectively shortened the development cycle of the die and reduced the design cost.

Key words: materials synthesis and processing technology, automobile panel, numerical simulation, finite element method, drawbead

CLC Number: 

  • TG386

Fig.1

Three-dimensional model of front floor"

Table 1

Stamping process plan"

工序号工序内容设备
OP10拉延J36-800
OP20修边冲孔JE36-400
OP30斜楔修边冲孔JE36-400
OP40翻边JE36-400

Fig.2

Tip point and tip angle"

Fig.3

Drop-shaped protrusions in process supplements"

Fig.4

Stamping process"

Fig.5

Finite element model"

Fig.6

Simulation result that drawbeads are not set"

Fig.7

Simulation results after drawbeads have been set"

Fig.8

Drawbead coefficient after drawbeads are optimized"

Fig.9

Simulation results of parts at 650 kN blank holder force"

Fig.10

Changes of force during drawing process"

Fig.11

Simulation results when die offset is 0.8 mm"

Fig.12

Trend of maximum failure as die offset changes"

Fig.13

Trend of thinning rate as coefficient of friction changes"

Fig.14

Simulation results after optimizing parameters"

Fig.15

Actual production of stampings"

Fig.16

Final simulation result"

Fig.17

Final stamping part"

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