Modelling of Solidification Deformation in Automotive Formed Parts

The accurate prediction of part deformation due to solidification in automotive formed parts is important to help achieve an efficient production. Forming processes are those where a molten preform is deformed to take the shape of a mould cavity and subsequently solidified. Tolerance issues are critical in automotive applications and therefore part deformation due to solidification needs to be controlled and optimized accordingly. Formed parts can have a wide range of deformations according to the conditions of solidification.

Both a small displacement and a large displacement formulation are developed for prediction of part deformation due to solidification. Experimental results obtained on a simple as well as complex automotive part are compared to determine whether the small displacement theory or the more complex approach is more appropriate.