Experimental study of surface defects on automotive doors during flanging and their numerical prediction

Port, A. Le; Thuillier, Sandrine; Manach, Pierre‐Yves; Garabed, J.

doi:10.1051/epjconf/20100615001

Cited by 2 publications

(2 citation statements)

References 3 publications

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“…This device flanges two perpendicular edges on a circular metallic sheet (Fig. The flanging load is obtained from raw data after removing a friction contribution [7]. The nominal configuration is a flanging height of 3 mm, a flanging radius of 0.5 mm, a corner radius of 4 mm and a blade radius of 2 mm.…”

Section: Experimental Studymentioning

confidence: 99%

Surface defects on thin sheets after flanging

Port¹,

Thuillier²,

Manach³

et al. 2011

AIP Conference Proceedings

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Several surface defects can develop on automotive exterior panels during the forming operations. They alter the vehicle aesthetic and their severity increases with the decrease of sheet thickness. These defects are difficult to characterize experimentally and reproduce numerically because of their depth below 0.5 mm and the complexity of the parts on which they develop. This study proposes a method that uses curvature of profiles to detect and characterize surface defects. The method has applied to a laboratory case to study the influence of tool parameters. Numerical simulations have been carried out and lead to a minimization of the severity of surface defects, but they allow to reproduce their shape.

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Section: Experimental Studymentioning

confidence: 99%

Surface defects on thin sheets after flanging

Port¹,

Thuillier²,

Manach³

et al. 2011

AIP Conference Proceedings

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show abstract

“…To enlarge the type of defects investigated, Le Port et al [4,5] developed a device to flange samples of reduced dimensions, compared to automotive opening parts, in order to reproduce defects that develop near the upper corner of an automotive door, after forming, flanging and springback [6]. Fig.…”

Section: Introductionmentioning

confidence: 99%

Surface Defects in Sheet Metal Forming: a Simulative Laboratory Device and Comparison with FE Analysis

Thuillier¹,

Port²,

Manach³

2011

AIP Conference Proceedings

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Surface defects are small concave imperfections that can develop during forming on outer convex panels of automotive parts like doors. They occur during springback steps, after drawing in the vicinity of bending over a curved line and flanging/hemming in the vicinity of the upper corner of a door. They can alter significantly the final quality of the automobile and it is of primary importance to deal with them as early as possible in the design of the forming tools. The aim of this work is to reproduce at the laboratory scale such a defect, in the case of the flanging along a curved edge, made of two orthogonal straight part of length 50 mm and joint by a curved line. A dedicated device has been designed and steel samples were tested. Each sample was measured initially (after laser cutting) and after flanging, with a 3D measuring machine. 2D profiles were extracted and the curvature was calculated. Surface defects were defined between points where the curvature sign changed. Isovalues of surface defect depth could then be plotted, thus displaying also the spatial geometry on the part surface. An experimental database has been created on the influence of process parameters like the flanging height and the flanging radius. Numerical simulations have been performed with the finite element code Abaqus to predict the occurrence of such surface defects and to analyze stress and strain distribution within the defect area.

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Experimental study of surface defects on automotive doors during flanging and their numerical prediction

Cited by 2 publications

References 3 publications

Surface defects on thin sheets after flanging

Surface defects on thin sheets after flanging

Surface Defects in Sheet Metal Forming: a Simulative Laboratory Device and Comparison with FE Analysis

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