Multistage Process Optimization for Manufacturing Automotive Component Using Finite Element Method

Automotive Rearshell is a critical component manufactured by multi stage deep drawing process. This work involves the optimization of manufacturing process of automotive component rearshell. Sensitivity analysis is conducted by using Taguchi design of experiment to check the robustness of the process towards material properties and the process parameters. It is found that material anisotropy and tool-blank interface friction are the most important parameter affecting the process significantly. Further in this work, the material grade and the stage involved in forming of the components is optimized. It is shown that by use of appropriate quality of steel sheet, the number of stages required for producing the Rearshell can be optimized.