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15 sifufi 3 n.o. - s.fu so
Forming Design of Fuel Tank Component Using Nonlinear Finite
Element Method
rn/m-5
fiiwiyn IOHO
IOHO
10540
Tsl'rf1'UBi8SjjJw«iiJJi:5if)iis'Mti*3iiJtfiJJiioi)i4jiJi'n0'Hin5siJ7tjni5iiiijilfii'MiJis;Hu uim
M 3
r,mi niafi i ihinQiaetrwuasuwnj'uirusTiJ n?aSfi 2 M
uasnififi 3 l^nftvoijijvo^iu^iu 2
2
Abstract
Many metal automotive pans are produced b\: stamping while there are many relevant parameters in the process
design. To be able to efficiently design the pan manufacturing, the designer needs to have sufficient knowledge and
understanding to metal part processing as well as to apply computer models before the implementation of physical tryouts
is carried out. This paper investigates stamping of a fuel tank component by applying finite element methods to analyze
the formability to determine the optimal forming process. The main parameters of interest are the part configuration and
blank configuration. A number of correction attempts are successively made to successfully form the part. From the
17
ilfi 15 fltfufl 3 n.o. - s.fi. 50
analysis of 3 case studies, it is found that the first case results wrinkling and tearing. The second case, which has
drawbead to correct wrinkles, results a reduction of wrinkling and tearing. The third case, which trims 2 edges of the
blank and modifies drawbead groove, results a better part than the previous 2 cases and passes the formability
requirements.
Keywords : Nonlinear Finite Element Method, Forming Design. Formability Analysis. Fuel Tank Component, Drawbead
(Automotive Industry)
s n inn
en ii an ij f nil i -sun swam 1001-3 snecuo-a
no o,?ia"iwniiiunawu?'uen'u
OUfl (Automotive Parts Industry) "JMHll
y v
Nflfll?)EJlll]ljfllJ1lJ (Stamping)
e-Added) M
(Mass Production)
(repeatable quality) [1] lumi
(Forming Design) iw?f'31Jtnt)14«fi
ina (Tearing) (Wrinkle) uns
(Springback) s (Die)
(Tooling)
21 fi [2]
11?iaoiJ9f ̂ (Tryouts)
(Finite Element Method w o FEM)
Dv-naform [3] lumrjifmsMmsmu
(detect free)
ntf«4lwjilfi i
X50cmX20 cm
UNU
ilisinai i m
18
1floSifu«tt)tJfniHa?imiM 3 fluviovj no (i) nssiy
aiflVUnl (Draw process); (2) ni£t)TUmiM1iail (Trim
process): (3) n?£inum?!in£| (Drill process)
Lower die
CAD w^«iuJ«iJii
(Upper Die) a d T U l l ' U H
(Lower Die)
(Lower Die) iJg'l
i (Binder)
ll~H~m
ilfi 15 offim 3 n.o. - s.n. 50
(Upper Die) Tl£
(Binder) !!ci£
(Lower Die) i
(Relative Motion) t
3.
SGTSE
MPa
44
Curve)
0.9 mm.
(Tensile Strength) inflflll 270 MPa
(Yield Strength) inflflll 150
(%Elongation) JJintTJI
(Flow
(Uniaxial Tensile Test) 1?lt)?niJ1?OTltiynw
[4-6]
a (Flow curve)
s" ( i )
K f)8 Strength coefficient llfl£ » H8 Hardening
exponent ?inmi1lniiTifins iHanjjn?it)Oti
(Regression Analysis) wl&hlbsinfU K = 354.08
N'mmMms n = 0.18737
Illfl 3 imet-3 Flo
19
m 15 oirufi 3 n.o. - s.n. 50
9w™2345
1
2345
12345
25.0025.0025.0025.0025.00
25.0025.0025.0025.0025.00
25.0025.0025.0025.0025.00
21.4221.4421.4021.4521.45
21.45L 21.48
21.4421 4521 43
21.4621 4721.4521.4621.47
0.90.90.90.90.9
0.90.9090.90.9
0 90.90.90.90.9
0.84
0.840.85
0.850.84
0.85
0.850.86
0.850.86
0840850.840.84
0.85
fn ln(Wo/Wx)0.15450.15360.15550.15320.1532
0.15320.15180.15360.15320.1541
0.15270 15220.15320.15270 1522
en Inlto/txl0.06900.06900.0572005720.06899
avg R90
0.057160.057160045460057160.04546
avg R«
0.068990057160.06899006899005716
avgR0
R2.24012.22662.72022.67942.2198
2.4172
2.67942.65503.37902.67943.3893
2.9564
2213126631221982.21312.6631
2.3944
4.1.
R)
IflJffl £w flO
£ flB
(R-value mo Plastic Strain Ratio Ml 0
(2)
(Width Strain) UctJ
(Thickness Strain) 'V<
(Pre-Processing) S
CAD
FEM <«?nimfllC!lbufl11J Dynaform
(Meshing)
ttJJJJOTIV! Planar Anisotropy
n o ~^ ^H>O 45 , ^ ,
-= ~^~
Ifltm Rav flB fhlijaEJ'UtH R-value; RO, /?45, Rm f!0 fil R-
value ^l?)ll?l?n3Jll%4T 0, 45, 90 0-3fTl fnUlSWIIflDe-Si y
iflW 2.6811
(Higher order elements) l l f l l
(3D -Shell
Element)
(Plane Stress)
4.
FEM)
Belytschko-Tsay [7](Nonlinear
(Large Aspect Ratio) FITS
20
(Rigid Body)
1 000-5000 mm/s
4.2.y
(Solving)
(Solver)
LS-DYNA [8] ^ifluWnm^DUlllJ Explicit
FEM
4.2. milifins-Hwasflaa^
(Post-Processing)
FEM
5.
5.1.
(Ideal Blank Configuration)
(Inverse Analysis) Iwllbsimu Dynaform
MSTEP M^ima^lwillfl 4
3 n.y. - s.n. 50
) Nonlinear
FEM
(Forming Limit Diagram wfo FLD)
?ifi [9]
ln 5 uaeu FLD ii
21
5.2.
Size) IfttlfrmUflWffi 680X1 220 mm.
6
(Blank
Size)
wufl«4l'Utlfi i
1 nttft-5 FLD 1ie^5flqutl|llnia Blank size
tlfi 15 yum 3 n.u. - s.fi. 50
tu unaj
(Blank V-U
a (Draw
Upper Die !!f1S
Binder 1'H2m'U?01J1llcH'l4iinn'U81)5\J^1\4<lJl£lJ1W 15
mm. 1l%J1?l'iU0^7'0^?l1BlJflll?ffl4?njJ'5tl?l 8 UflS 9
Drawbead
Tooling T l a i J Drawbead
10 Blank
22
ilfi 15 nuufi 3 n.o. - s.n. 50
\ 1
Section cut D-D (1:1)
Section cut A-A
Section cut F-F (1:1)
Section cut E-E (1:1)
Section cut B-B
Section cut C-C
12
23
tlfi IS flimfi 3 n.a. - s.n. 50
16 liff«'inil1'Ma«TUB-JllNt4laM£lumwll Blank
Size
Blank size
16
i? fi 2
ufintmlu'inu 30%
mi-s
8.
DBtlBllfjaj Engineering Technology Associates
Inc. (ETA) USA ?1slbtJ?mTJJfW1u'!lbufl1iJ Dynaform
in. t?TH11l
9.
[1]
[3]
Buranathiti, T., Cao, J., Xia, Z.C., and Chen, W.,
Probabilistic Design in a Sheet Metal Stamping
Process under Failure Analysis. The 6th International
Conference and Workshop on Numerical Simulation
of 3D Sheet Forming Processes NUMISHEET.
Detroit. Vol. A: pp. 867-872. 2005.
vnmii iJiajiii. miHammjaulu
21,
^ni) 2549
: u. 172-176. 2549.
ETA. 2005. Dynaform: User's Manual Version 5.2.
25
[4] Hill. R.. The Mathematical Theory of Plasticity.
Clarendon Press. Oxford. 355p. 1950.
[5] Hosford. W. F., and Caddell, R. M.. Metal Forming:
Mechanics and Metallurgy, Prentice-Hall, Inc. New-
Jersey, 3 64p, 1993.
[6] Wagoner. R.H.. and Chenot, J.-L.. Metal Forming
Analysis. Cambridge University Press. Cambridge.
376p. 2001.
o tlfi 15 otfufi 3 n.a. - s.n. 50
[7] Belytschko. T.. Lin. J.I.. and Tsai. C.S.. Explicit
Algorithms for One Point Quadrature Shell Element,
Computational Methods in Applied Mechanics and
Engineering, Vol. 42, pp. 225-251, 1984.
[8] LSTC, 2006, LS-DYNA: User's Manual. Version
970.
[9] Marciniak. Z.. and Kuczynski. K.. Limit Strains in
the Processes of Stretch-Forming Sheet Metal.
International Journal of Mechanical Science, Vol. 9,
9; pp. 609-620,1967.
26