Design and Forming Analysis of BIW Sheet Metal Component Using Autoform Simulation Software

Abstract

BIW is a frame member of a vehicle, which forms the chassis of vehicle. It has so many small features with ups and downs. The component is manufactured by draw type die. This is because to reduce the draw depth and it has two rows of draw beads. It seems to be difficult to form due to their small radius fillets. In this analysis, there is a need to find out the forming feasibility of this component and if not possible in single stage then we need to modify the die design with least modification and need to optimize the draw bead profile and draw radius in such a way that we can get the good component in a single stage itself. For thin and very big forming dies, we need to do gravity analysis. If our die face is profiled one, then we may need to do binder wrap analysis. The component wrap analysis results are taken to the forming analysis. After the forming analysis, if trimming is there means just before trimming analysis we have to do mesh Coarsening. Then the coarsened mesh and its results are taken for trimming analysis. The results of the trimming analysis are taken to the spring back analysis. From the results of the spring back analysis, further we can cross check the spring back of the real component. The analysis results obtained is used in sheet metal industry for metal forming process.