Integrated metal forming and vibration analysis of sheet metal parts

Abstract

Modern software programs are routinely used by industries to study the characteristics of and to reduce the cost of sheet metal parts that are used in automotive and other applications. Virtual simulations that are based on complex math models and state-of-the-art computational tools play a very important role in reducing the high costs associated with prototypes and the time to market the product. Formability studies of a sheet metal part determine if a part is formable by changing the factors that affect its formability. Vibration (or modal) analysis is performed to determine the frequency and mode shapes of the component or the assemblies. A gauge optimization study is performed to determine the optimum gage thickness assigned to components of an assembly while constraining the frequency of specified modes to a desired level. Usually these studies are done separately by different engineering departments in a typical automotive industry. In this paper, a single component from an instrument panel (IP) reinforcement assembly is analyzed by integrating the three different studies mentioned above. It was found that the thickness of the bracket and the coefficient of friction in the stamping process should be kept as low as possible to reduce the chance of splits occurring in the bracket. An optimum thickness for the same bracket as part of an assembly can also be determined using a gauge optimization study so that the assembly was stiff enough while minimizing its mass. Thus, an integrated analysis using simulation tools helps in better design of the parts and subassemblies, which ultimately helps stay in competition to produce quality products.