Optimal Design and Forming Analysis of the Stamping Process for Front Wall of Automobile Considering Springback Compensation Technology

In this paper, for the front wall of a certain automobile, the defects of drawing splits, excessive thinning and excessive springback in the sheet metal forming process are analyzed and predicted. The stamping process has been simulated. The influence of different technical parameters (blank holder force, stamping speed, die gap and friction coefficient) on the forming results was further investigated using the center composite experiment. Through preliminary finite element simulation, the main drawing defects and trimming springback were analyzed. The second-order response surface model was established to perform the multi-objective optimization design of the stamping process with a NGSA-II genetic algorithm. Based on the relevant simulation data, multiple springback compensations are performed on the die surface to reduce the final springback of the part to meet the requirements. Results have shown that through multi-objective optimization, the stamping dies development cycle is effectively shortened, and the design cost can be reduced. The use of simulation software can improve the reliability of the planning process and the design level of the die, and greatly reduce the machine downtime during production.