Formability Synchronous Emulation System For Automobile Panel Based On CATIA

Automobile panels with complicated structure and big overall dimensions always contain complex local flanging shape and demand high forming quality. In the product design phase, traditional methods are based on experience or simple theories to design product shape, which have high requirements on engineers and technicians. With the advancement of technology and computer technology, finite element simulation technology can help designers in the product design stage to consider various factors which affect the manufacturability of the products, obtain more accurate results in a very short period of time, save a lot of product development costs and shorten product development cycles.The research of this paper is aided by Chinese NC special projects:Stamping Dies of the whole body side panels, fenders and interiors of new environmentally friendly materials in C-Class car (No.2009ZX04013-031) and Chinese National Natural Science Foundation:Complex automotive structural parts multi-position progressive die strip design fast simulation model and the key algorithm (No.50905067). The paper employed CAA secondary development, designed and developed automobile panels' formability simulation system BEW (Blank Estimation Wizard) based on CATIA platform. By using the publication function of CATIA, the system can update the CAD model and CAM model synchronously to reduce the repeated CAE modeling time in the early product design phase and avoid loss of the data and accuracy. System is based on improved finite element inverse approach, which can calculate the blank shape of stamping parts quickly and predict the stress and strain distribution of the parts according to shape or technologic surface fo the workpiece. As an effective carrier of DFM, the system can be applied to the early design of automobile panel to help enterprises to improve new products' process quality and product quality, shorten product development time and save product development costs.The paper outlined and analyzed the development tools CAA and the development idea of finite element inverse approach of automobile panels' formability simulation system. On the basis of analying the automobile panels' structural features and forming process, the paper made a detailed needs analysis and designed the framework and interface of the system, setted the work flow initially, profiling the CATIA_BEW overall system design and implementation.The paper introduced the key technology of the CATIA_BEW system in detail. The system created and modified large amounts of data during the system operation process by employing the property operation interface of CAA.CATIA_BEW system integrates FASTAMP mesh subdivision device, which is quicker and reduce malformed units compared to CATIA's own subdivision device. What's more, the models can be updated synchronously by using CATIA's "publication" technology to avoid the complicated operations of the finite element model for the modification of the initial model.The paper verified the system's stability by comparing the simulation and experimental results of car floor and outside board. The error is small and solving speed is fast, which can meet the practical requirements of industry.