On the Die Face Design for Stamping an Automotive Engine Hood
|關鍵字:||模面設計;引擎蓋;餘肉設計;有限元素分析;沖壓角度;壓料面形狀;分模線形狀;設計流程;Die face design;engine hood;die addendum design;finite element analysis;stamping die angle;binder surface shape;die open line shape;design guideline||公開日期:||2010||摘要:||引擎蓋板零件為汽車售後服務市場的主要產品之ㄧ，但目前引擎蓋板之模面造型設計仍需仰賴模具師傅的經驗以及石膏模面的製作，才能設計出適當的餘肉造型。其設計過程中缺乏系統化與科學化的成形分析，因此對於模面造型的設計技術無法掌握，同時設計經驗亦無法有效的傳承。目前模具工業為因應市場快速反應的需求，縮短開發時程已是各模具廠必須積極努力的方向，因此傳統經驗法則也勢必將被淘汰。市售車型隨著製造技術的進步以及消費者對於外觀的注重，使得汽車外觀越來越多樣化，而且隨車型的不同外觀差異也隨之不同，因此模具廠在面臨多樣化且複雜的產品，走向數位化及科學化乃是必然的趨勢。
The engine hood is one of the major outer skin panels in an automobile body structure. The commercial quality requires the engine hood being free from cracks and wrinkles. In addition, the surface stretch at the center region of the engine hood needs to meet a strength requirement. Though the stamping technology on the forming of an engine hood has been developed by both the automotive industry and die makers, the success of the die design still relies mainly on the experience of professional engineers. Also, in response to the current market trends and the consumer concerns, the engine hoods look more and more diverse, making the die design even more difficult. Since the shape of an engine hood is mainly produced in the drawing operation, the die addendum design is the key to the success of manufacturing a defect free product. In order to analyze the addendum design, the part shapes of different engine hoods were first surveyed and the geometric characteristic features were identified and categorized. The existing die addendum designs corresponding to those engine hoods collected were also reviewed and the design parameters were constructed. The finite element analysis was then conducted to simulate the drawing process of an engine hood with flat addendum die face, i.e., without die addendum design. The defects occurred in the part were examined and the factors causing these defects were then analyzed. The preliminary study was then performed to examine the influence of the process parameters, such as stamping die angle, binder surface shape, and die open line shape on the defects occurred in the part. Based on the simulation results, the optimum design for the die addendum face was then investigated. The effects of the design parameters constructed in the present study on the occurrence of the defects were then examined and a systematic design guideline was proposed. In order to validate the proposed design guideline, actual engine hoods were stamped with the dies designed according to the finite element analysis. The production part shapes, thickness distributions, and the stretch at the central region were then compared with those obtained from the finite element simulations. The consistent agreement between the product parts and the simulation results confirms the validity of the design guide proposed in the present study for stamping an engine hood.
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