Study On The Process Of Forming And Springback Of Aluminum Alloy Door Outer

In the past 20 years,the world's energy problems have become more and more serious,which makes reducing automobile weight and fuel consumption become the key to improve competitiveness and promote sustainable development of automobile manufacturers in the situation of global car ownership exceeding 1 billion and increasing.The quality of car can reduce 30% to 40% by using aluminum alloy structure to replace the traditional steel structure.More and more car manufacturers began to use aluminum instead of the traditional steel.Aluminum alloy has been more and more widely used in the automotive industry.In order to meet the needs of automobile enterprises,door outer material,aluminum alloy 6016 series,was selected as research object,stamping forming numerical simulation of the aluminum alloy door outer and design and manufacturing of the mold and springback control were studied by using the UG/Autoform software.During the research,the limited stamping properties of the aluminum alloys attributed to their high yield strength and tensile strength compared with carbon steel's performance resulted in wrinkling,cracking,springback and other defects.Therefore,we have redesigned and modified the forming molds of the aluminum alloy door outer.The details are as follows:(1)To avoid the risk of cracking on the wall of the water cut,we will make the vertical wall bevel of the drawing die inclined 15 degree and enlarge the radius of fillet in the water cut area to 10.(2)For the cracking caused by flanging due to the poor local deformability of the aluminum alloy,we could eliminate the cracking caused by flanging by reducing the flanging height of the flanging mold.(3)The flanged retainer block was introduced to reduce the springback in the process of flanging because of the large spingback of aluminum alloy material.Based on the above problems,the aluminum alloy door outer forming program was optimized.We designed and modified the aluminum alloy door outer forming mold,sited tracking mold manufacturing,assembly and debugging process.During the debugging process,cracking at the water cut area,jamming of the work piece,flanging cracking and other problems are solved.The forming limit,reduction of thickness and springback detection of the aluminum alloy door outer that were manufactured have been carried out.The test results showed that the dimensional accuracy and quality of the door outer meet the requirements of the enterprise.