Abstract
Sheet metal forming is widely used in automotive, aviation, packaging, and household goods. It is most popular for the manifold technical feasibilities in manufacturing, high precision, mass production, and short processing time. Modern automotive concepts demand a weight reduction by using high strength materials and excellent crash performance, which requires innovative simulation techniques in the design and development phase as well as suitable processing chains. The conventional manufacturing planning method takes a lot of time, hence the Finite Element method (FEM) is applied to reduce the lead time. The FEM prediction accuracy depends on the proper selection of a material model, quality of input parameters, actual operating conditions, and many other factors. This study involves new developments in the sheet metal forming technology, the most influencing factors of the forming process and case studies to justify it. The first case study explains the springback analysis and springback compensation of AlMgSi (6xxx series)-panels. The second case study describes the thickness analysis and deformation behaviour of patchwork blanks for hot stamping processes.
Highlights
The body-in-white and most of the structural components of vehicles are manufactured by sheet metal forming
The Forming Limit Diagram (FLD) is a curve representing the upper limit of the safe zone, which is obtained by deforming sheets up to local necking in different strain conditions, like uniaxial compression, pure shear, uniaxial tension, plane strain, and equi-biaxial tension
The FE simulations of forming processes are helpful to reduce the lead time in the tool design and development stage
Summary
The body-in-white and most of the structural components of vehicles are manufactured by sheet metal forming. It offers a high strength to weight ratio compared to bulk metal forming. To achieve a high level of safety, some key parts like B-pillar, front side member, and cross members demand a high ratio of strength to weight. These requirements could be met with high strength aluminium alloy; due to lower formability behaviour, these alloys are still in the developmental stage [1, 2]. The initial study focuses on the mechanical testing and material modeling. Two case studies are presented showing the challenges in springback compensation and hot stamping of patchwork blanks
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