EFFECTIVE APPLICATION OF CAE FOR HEMMED CLOSURES THROUGHOUT THE PRODUCT DEVELOPMENT PROCESS

Paper #:
  • 2017-01-1310

Published:
  • 2017-03-28
Abstract:
The perceived quality of automotive closures (flushness and margin) is strongly affected by flanging and hemming of the outer panels and assembly respectively. To improve the quality of closures, the traditional hardware approach needs significant amount of time and costly die re-cuts and trials with prototype panels. Thus, such approach may delay the vehicle program and increase the overall investment cost. The proposed CAE methodology approach provides upfront design guidance to dies and panels, reduces time and cost associated with flanging and hemming trials necessary to improve overall quality of the closures. In this approach, as a first step, analytical formulae and design of experiments (DOE) are followed to estimate magnitude of design parameters of panels and dies to provide upfront design guidance. Secondly, finite element (FE) models are developed based on nominal design (uniform thickness) of the outer and inner panels, and are used to optimize the design parameters, such as flanging die radius, clearance, pre–hem angle and travel distance and to eliminate possible failure modes during flanging and hemming such as – large spring back angles, roll-in and out, warp, high tensile strain, splits, wrinkles, and hem-outs. In the third stage, CAE models of varying thickness of the inner and outer are used to tune design parameters and eliminate any presence of the failure modes to assure good quality hemmed closure. At the final stage, physical hardware test data are used to correlate simulation results and validate the effectiveness CAE methodology to guide design for its use to provide upfront design guidance and to reduce launch resources needed for closures of future vehicles. This forms a closed-loop simulation process that improves quality and confidence over time.
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