Sheet Metal Forming Analysis of an Automotive Part Using Finite Element Simulation
The purpose of the present research is to investigate and improve the quality of car brake booster deformed under drawing processes by using Finite Element (FE) program known as AutoForm. The materials are made from SPC270F with thickness 1.4 mm. and the initial diameter of 280 mm. The brake booster requires totally 9 production processes, including the sheet blanking, in the manufacture. Failure has found in the 4th draw in which cracking occurs at the bottom of cylinder. The material property assumed to be anisotropic, behaved according to Ludwik’s equation, and deformed rigid-plastic, which followed Hill’s yielding surface. The deformation for Forming Limit Diagram (FLD) was predicted by Keeler equation. Punch and die were assumed to be rigid during simulation. In this work, the process improvement focus mainly on the smallest change in die design which no lubricant required during the drawing processes. From the predicted results, the recommended punch diameter for the 1st draw should be extended to 111.4 mm while the new design for die’s diameter in the 1st draw is as large as 103 mm. However, punch’s height and its radius need to be varied in order to prevent the wrinkle as well. Since there is a little change in the new design while no more lubrication is required during the draw process, its can be improved in quality of finish product, cost reduction in lubricant consuming as well as the machining time to make a new punch.
Jiuba Wen, Fuxiao Chen, Ye Han and Huixuan Zhang
S. Suranuntchai and P. Kritboonyarit, "Sheet Metal Forming Analysis of an Automotive Part Using Finite Element Simulation", Applied Mechanics and Materials, Vol. 120, pp. 11-14, 2012