A blank optimization by effective reverse engineering and metal forming analysis

Abstract

Finite element methods help us to better understand the complex plastic deformation behaviour of sheet metal component during forming. The present work aim is to optimizing blank sheet of existing dimension 1535 X 1600 X 1.2 mm of a commercial vehicle component of engine tunnel bottom has to optimize by using finite element simulation without compromising safety and quality. A reverse engineering technology has been adopted for generating the CAD data of the forming tools. The forming simulation is carried out by using a commercially available explicit solver based software PAMSTAMP. While trying the reduced blank width, the blank holder force had been increased by about 15% (from the existing force 350kN to 400kN). The simulation results of the optimized blank sheet have been compared with the existing blank, which ensure the optimized blank is suitable for the engine tunnel bottom component without creating any defects and failures. Finite element method in sheet metal forming application have always helped us in weight savings and cost saving of automotive components.