A Study Based On CAE/CAI Integrated Method Of Sheet Metal Forming And Springback

Complex sheet metal panels forming widely used in the air conditioning industry, and is an important part of air conditioning. How to avoid forming defects, while improving the efficiency and accuracy of product testing, with the full assurance of product quality, reduce costs and shorten the development cycle, is of great significance. In recent years, the advanced manufacturing industry is engaging in a global production strategy-for simultaneous achievement of QCD (Quality, cost, delivery). Against this background, many corporations bring in CAI software to ensure quality and CAE software to reduce development cost and speed up the development pace. Of course, they can be helpful, but there are still some problems need to study:the results of CAE analysis are not effectively used and evaluated as we expected; CAI alone is not able to analyze reasons for defect in products, though it can accurately give the deformation of all parts; Die design, manufacturing, simulation-staff communication and collaboration difficult, resulting in low R&D efficiency. So we proposed a method of CAE/CAI integration to save these.The CAE/CAI integrated method is achieved through enhancing information sharing between CAE and CAI, and it makes CAE or CAI drawbacks compensated, which is greatly helpful for guiding the design of sheet metal forming.The main content of this paper is as follows:1. Finite element simulation of sheet metal forming and springback based on Dynaform.The typical air conditioning for the study, using Dynaform software by selecting the appropriate material model, the number of integration points and other parameters of the thickness direction and set a reasonable process parameters such as:pull drawbead, BHF, etc., simulation and analysis of sheet metal forming and springback process in order to predict forming defects and optimize the forming process. Generate grid data before and after springback and springback compensation.2. To detect the actual forming of the results and simulation results based on the CAI technology.Physical springback inspection base on CAI technology. The software Qualify detects physical data after digital processing. Comprehensive, can accurate and efficient assessments springback of products; In addition, this paper is based on CAI technology to detect the finite element simulation results data, which can early assess springback, conducive to the timely springback compensation, avoid premature tryout.3. Sheet metal forming and springback study based on integration of CAE/CAI.Explore CAE/CAI integration technology and build their model; Study new processes of it, and compared with the traditional process, the oretically first to demonstrate its superiority. What’s more, through a typical example of engineering application, in practice verify its feasibility and its outstanding advantages.