Three-Dimensional Binder Wrap Simulation Using ABAQUS/IMPLICIT

Draw simulation of automotive panels generally consists of two steps: binder wrap and punch contact. The binder wrap simulation while providing the necessary initial conditions for the ensuing punch contact simulation, is itself practically important. For instance, one can evaluate the binder design by examining whether the sheet shape inside the die cavity is buckle-free and/or the sheet on the binder is severely wrinkled. The physical process involved in the binder wrap is dominantly quasi-static and complex as it involves contact, friction and buckling phenomenon. Current binder wrap simulation in the automotive industry has been mainly carried out either using proprietary software or dynamic explicit codes with slow speed. This paper presents implicit-static finite element results using ABAQUS/IMPLICIT Code on the binder wrap of several doubly curved laboratory binders and comparisons with test data. Good correlation was obtained. An example of the binder wrap simulation for an actual automotive panel is also provided.