Abstract
A plate forging of a drawn cup with a flange including thickening of corners was developed to improve the stiffness of the cup. In a 3-stage stamping process, the bottom and flange corners of the cup with a flange were thickened by the plate forging. A circular blank was drawn with conical punches in the 1st and 2nd stages. In the 3rd stage, the bottom and flange corners were thickened by flattening the conical bottom of the cup with a flange. Both the bottom and flange corners of the cup were thickened by compressing the flange corner in the latter half of the 3rd stage. The amounts of thickening at both corners were improved by modification of intermediate shape. The thickening was concentrated around the two corners by preventing the thickening of the inclined portion. A wheel disk was formed by 6-stage stamping having the following three stages. The disk had 15% and 10% thickening at the bottom and flange corners, respectively, and the bending stiffness of the disk was increased. It was found that the proposed plate forging of sheet metal was considerably effective in increasing in the stiffness and reducing in the weight of automobile parts.
Highlights
The reduction in weight of automobile parts has an effect on the fuel consumption of automobiles
The cup with a flange was formed into a miniature wheel disk, and the bending stiffness of the disk was evaluated
Because the requisite stiffness and strength of the automobile parts are partially different, the optimized distributions of wall thickness in the parts lead to the reduction in weight having sufficient stiffness
Summary
The reduction in weight of automobile parts has an effect on the fuel consumption of automobiles. To increase the wall thickness around the bottom corner of the disk, Tan et al [11] have proposed a multi-stage stamping including thickening. A stamping process of tailor blank having locally thickening was developed [18, 19] and the tailor blanks were applied to increase the wall thickness around the bottom corner in the mild steel [18] and high strength steel disks [20]. The tailor blanks formed by the stamping process were effective in the increase of the wall thickness around the bottom corner. The cup with a flange was formed into a miniature wheel disk, and the bending stiffness of the disk was evaluated
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