Molding Process Simulation Analysis Of Thin-walled Parts And Optimization Of Process Parameters

Sheet metal stamping is a very important manufacturing technology, which has wide applications in industries such as automotive, aerospace, electrical and defense. Sheet metal stamping in automotive manufacturing is particularly important, because the most of automobile covers are composed of the sheet metal stamping. The process of the automobile covers stamping affects not only the vehicles appearance, but also affect the cost of automobile manufacturing and the new product development cycle, thus affecting the overall economic efficiency of the entire automotive products.Depending on the conventional experiences or stamping again and again to seek the best forming parameter and mold structure, people find that this method not only can not guarantee the quality of products, but also lengthen the development cycle and increase the cost. The fast development of computer technology makes the technology of sheet metal forming reach to a new step. The CAE software not only can discover the forming drawbacks in advance and analyze the reason of forming drawbacks, but also simplify and optimize the stamping scheme and the mold design scheme. At the same time, it can improve the quality of forming-products, short the time of studying and developing molds and reduce the production costs.Based on the project of Shenyang Aero Engine Corporation, this article using the professional stamping molding simulation software DYNAFORM, analyses the numerical simulation of a complex shape parts. Firstly, by using the Forming Limit Diagram (FLD) and the maximum reduction rate as the assessment standards, this article analyses the process of the sheet metal stamping and the defect generation, and then locates the stampings defect causes. Then by optimizing the process parameters and mold structure parameters, including the loading speed of the punch, the unit blank holder force, the friction coefficient and the mold gap, this article reduces the generation of defects and finds out the solution according to the simulation results. This article makes a springback simulation, too. It explores the influence of various process parameters on the springback displacement. Finally, according to the integrated stamping quality and the springback displacement, this article determines the optimal processing parameters and mold structure parameters:the loading speed of the punch is3000mm/s, the unit blank holder force (BHF) is1.5MPa, the friction coefficient is0.125, the mold gap is15%of the blank thickness.