Title: Combined finite element: forming limit diagram methodology for the development of automotive body stamped parts

Authors: G.L. Damoulis, E. Gomes, G.F. Batalha

Addresses: Department of Mechatronics and Mechanical Systems Engineering, Escola Politecnica – University of Sao Paulo, Av. Prof. Mello Moraes, 2231 05508.970 – Sao Paulo – SP, Brazil. ' Department of Mechatronics and Mechanical Systems Engineering, Escola Politecnica – University of Sao Paulo, Av. Prof. Mello Moraes, 2231 05508.970 – Sao Paulo – SP, Brazil. ' Department of Mechatronics and Mechanical Systems Engineering, Escola Politecnica – University of Sao Paulo, Av. Prof. Mello Moraes, 2231 05508.970 – Sao Paulo – SP, Brazil

Abstract: This paper describes how Finite Element Method (FEM) can be applied in conjunction with a forming limit diagram (FLD) methodology to lay out industrial sheet metal forming processes. A real part and its numerical model were simulated in accordance to real stamping conditions. The distribution of critical strain and thickness along the critical patches were comprehensively analysed. The FEM-FLD methodology and the experimental data revealed the critical areas of tearing and allowed identifying the modifications that need to be performed in the geometry of the tool in order to ensure the success of the industrial forming process.

Keywords: sheet metal forming; finite element method; FEM; forming limit diagram; FLD; numerical simulation; toll geometry; experimentation; strain; thickness; stamping; automotive body parts; automobile industry.

DOI: 10.1504/IJMMS.2008.020511

International Journal of Mechatronics and Manufacturing Systems, 2008 Vol.1 No.2/3, pp.264 - 281

Published online: 28 Sep 2008 *

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