This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Effective Application of CAE Guidance for Hemmed Closures Throughout the Vehicle Development Process
ISSN: 0148-7191, e-ISSN: 2688-3627
Published March 28, 2017 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
The perceived quality of automotive closures (flushness and margin) is strongly affected by flanging and hemming of the outer panels and assembly respectively. To improve the quality of closures, the traditional hardware approach needs significant amount of time and costly die re-cuts and trials with prototype panels. Thus, such approach may delay the vehicle program and increase the overall investment cost.
The proposed CAE methodology provides upfront design guidance to dies and panels, reduces time and increases cost savings associated with flanging and hemming while improving overall quality of the closures. In this proposed approach, as a first step, analytical formulae and design of experiments (DOE) are followed to estimate magnitude of design parameters of panels and dies as the upfront design guidance. Secondly, finite element (FE) models are developed based on nominal design (uniform thickness) of the outer and inner panels, and also used to optimize the design parameters, such as flanging die radius, clearance, etc., to eliminate failure modes during flanging and hemming, for example - large spring back angles, roll-in and out, etc. In the third stage, CAE models of varying thickness of the inner and outer are used to tune design parameters and eliminate any presence of the failure modes and to assure good quality of the hemmed closure. At the final stage, physical hardware test data are used to correlate simulation results and validate the effectiveness of CAE methodology to guide design. This forms a closed-loop process that improves simulation quality and confidence over time, and also resource and cost savings.
|Technical Paper||Full Vehicle Finite Element Model 4-Post Durability Analysis|
|Journal Article||The Potential of 3D-CAD Based Process – Optimization in the Automotive Concept Phase|
CitationKulkarni, H., Wang, Y., and Alanoly, J., "Effective Application of CAE Guidance for Hemmed Closures Throughout the Vehicle Development Process," SAE Technical Paper 2017-01-1310, 2017, https://doi.org/10.4271/2017-01-1310.
Data Sets - Support Documents
|Unnamed Dataset 1|
- Muderrisoglu , A. , Murata , M. , Ahmetoglu , M. , Kinzel , G. Altan , T. Bending, flanging, and hemming of aluminum sheet—an experimental study J. Mater Proc Technol 59 1 1996 10 17 10.1016/0924-0136(96)02281-9
- Livatyali , H. , Altan , T. Prediction and elimination of springback in straight flanging using computer aided design methods: Part 1. Experimental investigations J. Mater Proc Technol 117 1–2 2 November 2001 262 268 http://dx.doi.org/10.1016/S0924-0136(01)01164-5
- Livatyali , H. , Wu , H.C. , Altan , T. Prediction and elimination of springback in straight flanging using computer-aided design methods: Part 2: FEM predictions and tool design J. Mater Proc Technol 120 1–3 15 January 2002 348 354 http://dx.doi.org/10.1016/S0924-0136(01)01161-X
- Livatyali , H. , Kinzel , G. , Altan , T. Computer aided die design of straight flanging using approximate numerical analysis J. Mater Proc Technol 142 2 25 November 2003 532 543 http://dx.doi.org/10.1016/S0924-0136(03
- Livatyali , H. , Laxhuber , T. , Altan , T. Experimental investigation of forming defects in flat surface-convex edge hemming J. Mater Proc Technol 146 1 15 February 2004 20 27 http://dx.doi.org/10.1016/S0924-0136(03)00840-9
- Sartkulvanich , P. , Kroenauer , B. , Golle , R. , Konieczny , A. Altan , T. Finite element analysis of the effect of blanked edge quality upon stretch flanging of AHSS CIRP Annals -Manufacturing Technology 59 1 2010 279 282 http://dx.doi.org/10.1016/j.cirp.2010.03.108
- Song , N. , Qian , D. , Cao , J. , Liu , W. , Li , S. Effective Models for Prediction of Springback in Flanging J. Eng. Mater. Technol. 2000 123 4 456 461 10.1115/1.1395019
- Zhang , G. , Hao , H. , Wu , X. , Hu , S. , Harper , K , Faitel , W. An Experimental Investigation of Curved Surface-Straight Edge Hemming Journal of Manufacturing Processes 2 4 2000 241 246 1526–6125 http://dx.doi.org/10.1016/S1526-6125(00)70025-9
- Zhang , G. , Wu , X. , Hu , S. A Study on Fundamental Mechanisms of Warp and Recoil in Hemming J. Eng. Mater. Technol. 2000 123 4 436 441 10.1115/1.1396348
- Lin , G. , Koc , M. , Hu , S. , Cai , W. Three-Dimensional Numerical Simulations of Curved Edge-Curved Surface Hemming of Aluminum Alloy ASME Proceedings, IMECE2004-60705 503 511 10.1115/IMECE2004-60705
- Lin , G. , Lyer , K. , Hu , S. , Cai , W. , Marin , S.P. A computational design-of-experiments study of hemming processes for automotive aluminium alloys Journal of Engineering Manufacture October 1 2005 219 10 711 722 10.1243/095440505X32661
- Debuire , F. and Zwilling , V. Experimental and Numerical Approaches of Hemming: Application on Steel and Aluminum6016 SAE Technical Paper 2002-01-2084 2002 10.4271/2002-01-2084
- Svensson , M. , Mattiasson , K. Three-dimensional simulation of hemming with the explicit FE-method J. Mater Proc Technol 128 1–3 6 October 2002 142 154 http://dx.doi.org/10.1016/S0924-0136(02)00441-7
- Zeng , D. and Xia , Z. Stretch Flanging Formability Prediction and Shape Optimization SAE Technical Paper 2006-01-0351 2006 10.4271/2006-01-0351
- Lin , G. , Hu , S. , Cai , W. Evaluation of Formability in Bending/Hemming of Aluminum Alloys Using Plane-Strain Tensile Tests J. Manuf. Sci. Eng. 2009 131 5 10.1115/1.3123316
- Wanintradul , C. , Golovashchenko , S. , Gillard , A. , Smith , L. Hemming process with counteraction force to prevent creepage Journal of Manufacturing Processes 16 3 August 2014 379 390 http://dx.doi.org/10.1016/j.jmapro.2014.04.003
- Asnafi , N. On stretch and shrink flanging of sheet aluminium by fluid forming Journal of Material Processing Technology 96 1999 198 214 http://dx.doi.org/10.1016/S0924-0136(99)00352-0
- Wang , C. T. , Kinzel , G. , and Altan , T. Failure and Wrinkling criteria and mathematical modeling of shrink and stretch flanging operations in sheet – metal forming Journal of Material Processing Technology 53 1995 759 780 http://dx.doi.org/10.1016/0924-0136(94)01766-T