Application of FEA in Stamping Auto Underbody Parts

The complex auto underbody components need a long process of die design and tryout, some times need several to hundred times of costly trial-and-error to get required stamping parts. It is very critical to the die design how to decide and evaluate the die shapes of each forming stage and how to distribute the deformations between preform(s) and form for multi-stage forming. Combination of simulations for each forming stage using Dynaform and shape design using Catia can reduce the time and cost of die tryout, and make the die design optimization possible. The stampability of the part can be evaluated. The optimized die shapes and deformation distribution can be obtained. The main forming failures, such as wrinkles/double metals and cracks can be solved at die design stage. This paper attempts to show some applications of simulation techniques combined with shape design in the die design.