Structural Design of an Auto Panel Die Component Based on the Contact Pressure Using Topology Optimization

The main motivation in stamping die industry and academia is panel quality and formability issues rather than the weight and cost of the die. A product should be designed according to the loads that it can be faced in service condition. But somehow this rule is not valid for stamping die design since the minimum distance between the ribs is based on the standards and location and pattern of the ribs which are depending primarily on the company experience. In this work, an auto panel drawing die design is investigated numerically whether it is overdesigned or not. The loads on the die surfaces are calculated by numerical methods. When a panel is drawn between upper and lower die, the contact pressure (CP) occurs on the interface surfaces due to this interaction. Since CP is a vital parameter and it is almost impossible to measure it by experimental methods, it is validated by two different numerical codes. The CP values obtained from Autoform® quasi-static solution are compared with Abaqus® transient forming analysis solution. Topology optimization is applied on the lower die by using the estimated CP loads. Von-Mises stress, elastic deformation and volume are compared between current and optimized die geometry. Panel thickness variation is also investigated in longitudinal and transverse directions.

Study on Microstructure and Formability of DP Steel of Lightweight Automobile

Dual phase (DP) steel is a high strength steel for auto-panel. In this paper, mechanical property, forming ability of high strength steel DP450 are studied by experiments and compared with those of steel MS6000. And theoretical research on predicting the forming limit of steel DP450 by the NADDRG model. The established mathematic model for relativity is of practical usefulness. Experimental results reveal that the yield strength of steel DP450 is about 7.2% lower than the MS6000, and the break strength increases by 18.9%, while the elongation increases by 19%. The results show that mechanical property of high strength steel DP450 is better than that of MS6000, while forming ability of DP450 is not lower than that of MS6000.

Accurate Prediction Approach of 3D Trimming Line for Auto Panel Part

It is difficult to obtain 3D trimming line using traditional prediction methods for auto panel parts. An initial geometrical development method with element layer is proposed based on one step inverse analysis theory for this problem. The flange mesh can be unfold onto the die surface layer by layer according to nodal adjacent element relation, then the above development mesh is smoothed by mesh smoothing method with sliding constraint surface in order to delete overlap and distorted mesh, the 3D initial mesh can be obtained for one step inverse analysis method. The accurate 3D trimming line of auto panel part can be achieved by plasticity iteration of one step inverse analysis. A typical real part of 3D trimming line prediction is selected to prove this method, the comparison results between the simulated and experimental values show that this method has enough precision and can handle complex parts, satisfies the engineering practical demands.

Numerical Simulation of the Stamping Forming Process of Alloy Automobile Panel

6xxx based alloy auto body sheet will be used widely in the future, but, in the recent, one of the difficulty in practice is its poor formability. In this paper properties parameters of 6061 aluminum alloy sheet are investigated by means of examination; By using machine performance parameters of 6061 aluminum alloy, finite element software eta/DYNAFORM of Sheet Forming make the numerical simulation of auto deck lid outer panel .Stress, plastic strain, thick variety are analyzed; and the wrinkling and cracking prone areas identified. Therefore, the effective reference can be provided for design of forming process of 6xxx Based Alloy auto panel.