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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2008

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Applicability valuation for evaluation of surface deflection in automotive outer panels

Park D. H., Bae W. R., Jeong H. J., So B. S., Ko T. J., Yarlagadda P. K. D. V.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 31, nr 2

558-564

Purpose: Upon unloading in a forming process there is elastic recovery, which is the release of the elastic strains and the redistribution of the residual stresses through the thickness direction, thus producing surface deflection. It causes changes in shape and dimensions that can create major problem in the external appearance of outer panels. Thus surface deflection prediction is an important issue in sheet metal forming industry. Many factors could affect surface deflection in the process, such as material variations in mechanical properties, sheet thickness, tool geometry, processing parameters and lubricant condition. Design/methodology/approach: Numerical simulation of process was performed by the use of finite element method, paying attention particularly to the thickness distribution and surface deflection of the drawn outer panel and the outline flange during forming. Simulation procedures of automotive outer panel as large size shape are as follows; 1) Acquisition of drawing parts 2) Laser scanning for generating CAD model 3) CAD model generation 4) Simulation model operation 5) Simulation execution and analyses of simulation results. Findings: The development of automation in stamping and assembly processes of automobile manufacture will require an excellent surface quality of formed panels and also their accurate dimensions. Practical implications: The use of high strength steel sheets in the manufacturing of automobile outer panels has increased in the automotive industry over the years because of its lightweight and fuel-efficient improvement. But one of the major concerns of stamping is surface deflection in the formed outer panels. Hence, to be cost effective, accurate prediction must be made of its formability. The automotive industry places rigid constraints on final shape and dimensional tolerances as well as external appearance quality of outer panels. The numerical simulation makes it possible to design and optimize the total process to a level, which can't be reached by traditional theoretical and experimental methods. Originality/value: Computer simulations can be used to determine the influence from variations in material properties and process parameters.