Abstract
In order to obtain the optimum technological parameters of fender forming, the finite element analysis software DYNAFORM is used to simulate the drawing process of fender in this paper. The orthogonal test is designed and completed. On the basis of the orthogonal test, Taguchi method is used to design the orthogonal inner table, and the SNR of each factor at each level is calculated. The results of Taguchi method are analyzed with variance analysis, and the adjustable influencing variables and influence factors on quality stability that affect the forming quality of the fender are obtained. Experimental optimization of the adjustable variables is carried out again to obtain the optimal combination of process parameters that affect the shaping quality of the fender. The optimal combination of process parameters is as follows: blank holder force is 120 kN, model clearance is 1.0 t (t represents sheet thickness), friction coefficient is 0.11, and radius of die is 6 mm. Finally, the experimental results show that the fender manufactured with this combination of process parameters has better performance.
Highlights
Automobile panels are important parts of automobile, most of them are formed by sheet metal stamping, which has the characteristics of complex shape, large structure size, and high surface quality requirements. e fender is a covering panel that is installed on the left and right sides of an automobile body to cover the wheels
Blank Size Blank design module in the finite element analysis software DYNAFORM is used to design blank. e IGES 3D model is imported into DYNAFORM and meshing. e shape and size of the blank are calculated from the part mold, and the appropriate shape of the blank is obtained through DYNAFORM simulation. e inflow resistance of material sheet can be adjusted and the stress distribution is improved when the upper die is pressed by selecting suitable draw-bead structure and arrangement, and the overall material flow speed of panels tends to be stable, so as to improve the forming quality of panels [7]. rough setting of DYNAFORM pretreatment, the thickness of the blank is set to 0.5 mm, which is consistent with the actual sheet
Taguchi method is used to optimize the process parameters of the fender, and the results show that
Summary
Automobile panels are important parts of automobile, most of them are formed by sheet metal stamping, which has the characteristics of complex shape, large structure size, and high surface quality requirements. e fender is a covering panel that is installed on the left and right sides of an automobile body to cover the wheels. Automobile panels are important parts of automobile, most of them are formed by sheet metal stamping, which has the characteristics of complex shape, large structure size, and high surface quality requirements. Liu et al has used numerical simulation to analyze the forming process of automobile fender and improved the forming quality [2]. Ma have used AUTOFORM to simulate the stamping process of automobile fender and optimized the die structure [3]. Liu and Huang et al have studied the forming performance of automobile fender by using DYNAFORM and compared the virtual testing die results with the actual testing die [4]. E optimization analysis results are compared with the actual forming parts to provide basis for testing die and actual production Taguchi method is used to optimize the forming parameters of the fender, and the optimal parameter combination of fender is obtained. e optimization analysis results are compared with the actual forming parts to provide basis for testing die and actual production
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