A framework for predicting subtle surface distortion in sheet metal flanging

Yonggang Huang*, N. Mahayotsanun, Jian Cao, W. Lee, H. P. Wang, S. Xu

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The subtle distortions after flanging operations on outer automotive panels are highly undesirable on class-1 finish panels. Since existing finite element software do not have the ability to accurately predict or capture these subtle distortions, die designers rely on expensive and time-consuming physical tryouts to verify and adjust their design. Thus, this work aimed to gain an understanding of the distortion behavior and to develop a numerical tool that captures these subtle surface distortions. Both theoretical and experimental approaches were carried out. The energy-based buckling predictor was developed as a post-processor of numerical simulations to assess the distortion tendency. The experimental work consisted of pre-stretching, trimming and flanging. Surface scanning was conducted to verify the applicability of the buckling predictor. The comparison between the predictions and the experimental results showed that the predictor could predict surface distortions in the flanged panels.

Original languageEnglish (US)
Title of host publicationTransactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME
Pages403-410
Number of pages8
Volume38
StatePublished - Nov 16 2010
Event38th Annual North American Manufacturing Research Conference, NAMRC 38 - Kingston, ON, Canada
Duration: May 25 2010May 28 2010

Other

Other38th Annual North American Manufacturing Research Conference, NAMRC 38
CountryCanada
CityKingston, ON
Period5/25/105/28/10

Fingerprint

Sheet metal
Buckling
Trimming
Stretching
Scanning
Computer simulation

Keywords

  • Buckling
  • Flanging
  • Sheet metal forming
  • Surface distortion

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

Cite this

Huang, Y., Mahayotsanun, N., Cao, J., Lee, W., Wang, H. P., & Xu, S. (2010). A framework for predicting subtle surface distortion in sheet metal flanging. In Transactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME (Vol. 38, pp. 403-410)
Huang, Yonggang ; Mahayotsanun, N. ; Cao, Jian ; Lee, W. ; Wang, H. P. ; Xu, S. / A framework for predicting subtle surface distortion in sheet metal flanging. Transactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME. Vol. 38 2010. pp. 403-410
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Huang, Y, Mahayotsanun, N, Cao, J, Lee, W, Wang, HP & Xu, S 2010, A framework for predicting subtle surface distortion in sheet metal flanging. in Transactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME. vol. 38, pp. 403-410, 38th Annual North American Manufacturing Research Conference, NAMRC 38, Kingston, ON, Canada, 5/25/10.

A framework for predicting subtle surface distortion in sheet metal flanging. / Huang, Yonggang; Mahayotsanun, N.; Cao, Jian; Lee, W.; Wang, H. P.; Xu, S.

Transactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME. Vol. 38 2010. p. 403-410.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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AB - The subtle distortions after flanging operations on outer automotive panels are highly undesirable on class-1 finish panels. Since existing finite element software do not have the ability to accurately predict or capture these subtle distortions, die designers rely on expensive and time-consuming physical tryouts to verify and adjust their design. Thus, this work aimed to gain an understanding of the distortion behavior and to develop a numerical tool that captures these subtle surface distortions. Both theoretical and experimental approaches were carried out. The energy-based buckling predictor was developed as a post-processor of numerical simulations to assess the distortion tendency. The experimental work consisted of pre-stretching, trimming and flanging. Surface scanning was conducted to verify the applicability of the buckling predictor. The comparison between the predictions and the experimental results showed that the predictor could predict surface distortions in the flanged panels.

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Huang Y, Mahayotsanun N, Cao J, Lee W, Wang HP, Xu S. A framework for predicting subtle surface distortion in sheet metal flanging. In Transactions of the North American Manufacturing Research Institution of SME 2010, NAMRI/SME. Vol. 38. 2010. p. 403-410