Numerical Prediction of Forming Car Body Parts with Emphasis on Springback

Abstract

Numerical simulation is an important tool which can be used for designing parts and production processes. Springback prediction, with the use of numerical simulation, is essential for the reduction of tool try-outs through the design of the forming tools with die compensation, therefore, increasing the dimensional accuracy of stamped parts and reducing manufacturing costs. In this work, numerical simulation was used for performing the springback analysis of car body stamping made of aluminium alloy AA6451-T4. The finite element analysis (FEM) based software PAM-STAMP 2G was used for performing the forming and springback simulations. These predictions were conducted with various combinations of material models to achieve accurate springback prediction results. Six types of yield functions (Barlat89, Barlat2000, Vegter-Lite, Hill90, Hill48 isotropic, and Hill48 orthotropic) were used in combination with the Voce hardening model. Springback analysis was conducted in three sections of the formed part; the numerical results were compared with the experimental values. It was found that the combinations of Barlat’s yield functions and the Voce hardening law were most accurate in terms of springback prediction. Additionally, it was found that the phenomena that were investigated, which are required for the determination of the kinematic hardening model, such as the change of Young’s modulus E, the transient behaviour, work-hardening stagnation, and permanent softening, were not observed in the aluminium alloy studied.