Comparison of Formability between Steel and Aluminum Fender Panels

Reducing a vehicle’s weight is an efficient method to reduce energy consumption. Aluminum alloy is the best material for lightweight automobiles. However, the poor formability of aluminum means that it is difficult to develop stamping dies. This study designs a suitable forming tool for aluminum fenders. A simulation and an experiment are used to analyze the formability of aluminum fenders. A theoretical calculation, experimental testing, and sampling comparison are used to verify the design. The material properties of steel and aluminum are firstly studied and compared. The results show that a traditional S-type blank die face design is not suitable for aluminum because of its low tensile strength and the potential for elongation. A relatively flat trapezoid blank die face design is proposed to smooth the variation. However, a flat die face for a trapezoidal blank limits stretching, so another design is essential to improve the formability. Finally, the dimension of the drawbead controls the friction between the blank and the binder. The experimental results are in good agreement with the simulation results. The computer-aided engineering (CAE) analysis data will be kept for future reference to allow the design of a drawing die for the aluminum fender panels.