Research On Defect Formation Mechanisms And Control Of Sharp Edge Forming Parts For Automobile Coverings

The sharp edge forming technology for automotive body panels is a challenging and important technology in modern car manufacturing.It provides unique design options for the exterior of cars and enhances their aesthetics and comfort.However,various defects such as wrinkles,cracks,and slip lines can occur during the sharp edge forming process,which can reduce the quality of the product and even lead to component failure.These defects pose challenges to the forming process.Therefore,controlling the formation of sharp edge forming defects has become a pressing issue for automotive manufacturing companies.This article uses Auto Form R7 as a tool and employs experimental design and simulation analysis methods to study the material science aspects of sharp edge forming during the formation of components.The article discusses the formation mechanism of component defects,proposes defect control measures and methods,and analyzes their effectiveness.The specific research contents are as follows:(1)The development of automotive sharp edge forming technology and the application of Auto Form software are introduced.The key technologies and challenges in automotive sharp edge forming are summarized,including sharp edge forming mold surface design,material mechanics and deformation control technology during sharp edge forming,optimization and control of sharp edge forming parameters,simulation and analysis technology during sharp edge forming,and automated control technology for sharp edge forming processes.(2)Using the design of the automotive engine hood sharp edge outer panel stamping process as an example,the design,process verification,and simulation of the automotive exterior panel stamping process are analyzed,along with the types and distribution patterns of forming defects and the control measures and effectiveness of forming defects.The simulation results show that the main factor affecting defects at sharp edges is the slip line.By optimizing the mold surface design,the length of the slip line can be reduced,preventing it from exceeding the sharp edge radius and eliminating the impact on the exterior quality of the product.(3)Based on the preliminary simulation results,the formation mechanism of sharp edge forming defects is analyzed,and defect control strategies are proposed.Through case studies of sharp edge forming defect control and analysis of the impact of various factors on defects,the range of orthogonal experimental design of multiple process parameters is determined.The effectiveness of the proposed defect control methods is verified through experiments,and actual case guidance shows that the use of appropriate control methods for different types of defects can effectively reduce their occurrence rate and improve the quality of components.The research shows that by controlling the sharp edge forming process parameters,optimizing mold design and manufacturing,and combining numerical simulation technology,sharp edge forming defects can be effectively eliminated,and the exterior quality and performance of automotive body panels can be improved.This study has certain reference value and practical significance for solving sharp edge forming defect control in the automotive industry and promoting the development of automotive manufacturing technology.