Integrated metal forming, vibration analysis, and thickness optimization of sheet metal parts

Abstract

Modern software programs can be used to study the characteristics and reduce the cost of sheet metal parts that are used in many applications. Numerous tests can be performed on these parts using the virtual simulations. One example is a sheet metal forming analysis to determine if the part is formable and the factors that affect its formability. Another is modal analysis to determine the frequency and mode shapes of the component or of assemblies. A gauge optimization study can then be performed to determine the optimum thickness to assign to components of an assembly while constraining the frequency of specified modes to a desired level. For this paper one component from an instrument panel (IP) reinforcement assembly is analyzed and it was found that the thickness of the bracket and the coefficient of friction in the stamping process should be kept as low as possible to reduce the chance of splits occurring in the bracket. An optimum thickness for the same bracket as part of an assembly was also determined using a gauge optimization study so that the assembly was stiff enough while minimizing its mass. Thus, an integrated analysis using simulation tools helps in better design of the parts and subassemblies, which ultimately helps stay in competition to produce quality products. © Organizing Committee of TMCE 2010 Symposium.