Utilization of Advanced Computational Methods to Predict Spring-back of Aluminium Alloys in Automotive Industry

Abstract

The automotive industry is one of the most dynamically developing segments of the industrial production all over the World. The implementation of still more demanding emission limits for newly developed cars forces car producers to continuously reduce the fuel consumption of cars. As one possibility there are used hybrid drive units in combination with a redesigning the car-body while maintaining the highest possible level of vehicle safety. Because of these reasons, the automotive industry has been increasingly forced to implement and process low density (lightweight) alloys -including aluminium-based alloys. So these materials are subjected to high demands both in terms of mechanical properties and technological workability in the mass production process. The utilization of mathematical modelling (numerical simulations) at production processes is now one of the standards in all phases at designing and production of the car-body and allows implementation of variable shape modifications in a relatively short time scale. Moreover, it enable to detect the potential production problems as well. In this paper, the influence of the kinematic hardening model on the accuracy of spring-back prediction is shown in comparison with the commonly used isotropic hardening model. For deformation analysis, a simple workpiece having "U-shape" of EN AW 6111 material was used. Such aluminium alloys is used for production car-body panels in the automotive industry. Achieved accuracy of numerical simulation results is here evaluated by the comparison shape obtained by numerical simulations and shape of experimentally bended workpiece.

Weight reduction in an AA2017 aluminum alloy part through the gas forming process of a blank with a variable thickness

“…In order to lighten parts aluminium alloys, which have a high strength to weight ratio, are the most commonly used metal materials. They are manufactured through plastic deformation processes for both aerospace and automotive applications [2]. Moreover, the use of tailored blanks for plastic deformation processes also substantially contributes to this objective [3].…”