Drawing a complex door molding the numerical simulation
Abstract
The sheet metal parts have been widely used in the automobile,aerospace and electronics industrics owing to their light weight,great interchangeability,good surface finish and low cost.The deep drawing process is a main method used in mass production of sheet metal parts.Deep drawing process contains very complicated physical phenomena,involves three nonlinear problems,they are material,geometry and boundary of the mechangics science.The development of tooling for the sheet metal deep drawing is a time-consuming and expensive “trial and error”process by traditional way.In this paper finite element(FE)modeling is adopted to analyze this process in order to reduce the time and cost of tooling development.
Wrinkling and cracking are major invalidation in the deep drawing process of the complex drawing part, because of hard calculating its deformation extent, local and outside adopt traditional press currently on board produce, mostly takes deep drawing shape once, for lowering the risk and cost of the die design production, the industry progresses a nation, such as Japan, Germany, American etc.,, before the die design production, usually making use of finite element analysis simulate the punching process, predict the wrinkling and cracking in the deep drawing process, modifies the structure size of the stamping to make it match the punching process condition of the stamping. But the premise of the finite element analysis is building up the 3D CAD model, and duct into the finite element analysis software by the IGES format, then analysis and estimate the possibility of wrinkling and cracking.
This text uses an automobile panels’door frame for instance, discuss the establishment of 3D CAD model and the process of finite element analysis. Analysis respectively from forming zone, safety zone, major strain etc, the result enunciation existence strain concentration zone, can shorten the exploitation period of automobile panels, lower the cost of production.
Keywords sheet metal;automobile panels;CAD model;finite element analysis
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