Progressive multistep press forming of a truss core panel for floor structure of electric vehicle

Abstract

The truss core panel is a composite of double-layer triangular core panels, and has characteristics of high strength and low weight. However, problems of fracturing and a limited forming height arise because of the complex shape of the panel. From research on a hemispherical shape transition mould, we propose a new pyramid transition shape for the die used in the progressive press forming. Employing the finite element method, we simulated progressive press deforming and determined the effectiveness of forming. The new mould greatly improves the thickness distribution and forming height of the truss core panel. Additionally, we manufactured a model of the die and processed a truss core panel, and compared the thickness distributions of simulated and processed truss core panels. The thickness distributions of simulated and manufactured panels were similar, demonstrating that simulation can be used to study the forming problem of a truss core panel.