Modeling and Experiment on Roll-Hemming Forming Process of Aluminum Alloy Sheet with Adhesive

doi:10.16183/j.cnki.jsjtu.2021.198

Abstract

Abstract:

In the roll-hemming forming process of door cover, the non-metallic flanging adhesive and the interaction between light metal and flanging adhesive will affect the manufacturing accuracy and performance of the door cover, and increase the difficulty of roll-hemming forming and quality control of automobile body sheet with adhesive. Therefore, a numerical analysis model for roll-hemming forming of aluminum alloy sheet with adhesive was proposed based on the finite element method and the smooth particle hydrodynamic (FEM-SPH) method. First, SPH was used to simulate the extrusion flow process of the flanging adhesive, and a roll-hemming simulation model of sheet metal with adhesive was established in combination with FEM. Then, an experimental platform for two-pass roll-hemming forming of aluminum alloy sheet with adhesive was built, and the roll-hemming loss and surface wave coefficient were taken as the roll-hemming forming quality index to analysis and verify the validity of the numerical model. After that, the quality change between the first pass and the last pass and the key process parameters affecting quality were studied based on the orthogonal test method. Finally, the fitting relationship between roll-hemming forming quality and process parameters was established. The results show that the roll-hemming loss and the surface wave coefficient of the last pass are reduced compared with the first pass. The process parameters that affect the surface wave coefficient in descending order are flanging height, fillet radius, TCP-RTP value, and roller diameter. The process parameters that affect the roll-hemming loss in descending order are TCP-RTP value, fillet radius, flanging height, and roller diameter. The fitting relationship can support the prediction of roll-hemming forming quality of aluminum alloy sheet with adhesive.

Key words: roll-hemming process, flanging adhesive, aluminum alloy sheet, finite element method and smooth particle hydrodynamic (FEM-SPH) method, car door cover

CLC Number:

U463.82

LI Yuanhui, LI Jianjun, WANG Shunchao, ZHANG Longyao, ZHU Wenfeng. Modeling and Experiment on Roll-Hemming Forming Process of Aluminum Alloy Sheet with Adhesive[J]. Journal of Shanghai Jiao Tong University, 2022, 56(4): 532-542.

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滚边形式	实验1			实验2			实验3
滚边形式	实验	仿真	误差/%	实验	仿真	误差/%	实验	仿真	误差/%
预滚边	0.320	0.350	9.4	0.142	0.154	8.5	0.063	0.061	3.2
终滚边	0.109	0.103	5.5	0.060	0.065	8.3	0.068	0.069	1.5

滚边形式	实验1			实验2			实验3
滚边形式	实验/mm	仿真/mm	误差/%	实验/mm	仿真/mm	误差/%	实验/mm	仿真/mm	误差/%
预滚边	0.263	0.260	1.1	-0.065	-0.063	3.1	-0.014	-0.016	11.9
终滚边	0.245	0.247	0.8	-0.087	-0.085	2.3	-0.064	-0.067	4.7

因素	Fa	质量指标
		s		ε
		F值	显著性水平	F值	显著性水平
L	F0.1(3, 3)=5.39	7.586394684	*	25.15533164	***
d	F0.05(3, 3)=9.28	3.698513166		0.532719543
H	F0.025(3, 3)=15.44	91.93424461	****	2.012180586
R	F0.01(3, 3)=29.46	7.626043159	*	8.910506751	*
误差		1		1