Aluminum Sheet Springback (Side-Wall-Curl) Study 2017-01-0396

Vehicle weight reduction is a significant challenge for the modern automotive industry. In recent years, the amount of vehicular components constructed from aluminum alloy has increased due to its light weighting capabilities. Automotive manufacturing processes, predominantly those utilizing various stamping applications, require a thorough understanding of aluminum fracture predictions methods, in order to accurately simulate the process using Finite Element Method (FEM) software or use it in automotive engineering manufacture. This paper presents the strain distribution of A5182 aluminum samples after punch impact under various conditions by Digital Image Correlation (DIC) system, its software also measured the complete strain history, in addition to sample curvature after it was impacted; therefore obtaining the data required to determine the amount of side-wall-curl (Aluminum sheet springback) present after formation. A thorough understanding of this phenomenon is essential, seeing that any curvature in the part wall can affect quality and sustainability. It is necessary to compensate for this during stamping operations; especially when conducting simulation validation. The data collected during this experimental procedure, in addition to the complete strain history around the punch head, will be used to establish a Finite Element Analysis (FEA) model for side wall curl (Aluminum sheet springback). This data is crucial for simulation validation within the automotive stamping industry, in addition to providing a more thorough understanding of side wall curl, which will greatly benefit future part production. In addition, this will ensure A5182 Aluminum vehicular components can be utilized in production; therefore contributing to the overall success of vehicle weight reduction. In addition, the DIC method also can be applied to other engineering applications within the industry, due to its broad range of capabilities and advantage.