Numerical Simulation and Experiment of Roller Hemming-compression with Flat Surface-curved Edge Aluminum Alloy Sheet Based on SPH

doi:10.3901/JME.2020.24.061

Abstract

Abstract: Roller hemming-compression is an assembly process to realize high quality connection between inner and outer panels of auto-body, and its forming mechanism and quality prediction have always been the research focus. In order to quantitatively reveal the effect mechanism, the smoothed particle hydrodynamics(SPH) is introduced to simulate the adhesive, and a simulation prediction model is established, in line with the engineering. The feasibility is verified by comparing with the traditional Euler method. The finite element method(FEM) is used to simulate the aluminum alloy sheet with the typical flat surface-curved edge., and the SPH-FEM coupled numerical model is established. The process is simulated and analyzed, and verified by experiments. Then, the mathematical model of the interaction effect of adhesive viscosity, squeeze speed and adhesive thickness on forming quality is established by response surface method. Results show that the roll-in and maximum elastic-plastic deformation with adhesive decrease relatively, compared with the model without adhesive. The influence of the thickness of the adhesive on the forming quality is significant, followed by the viscosity of the adhesive, and the squeezing speed is not significant. The modeling method based on SPH solves the difficult quantification problem of forming with adhesive, and provides a important theoretical basis for process optimization and improvement of manufacturing accuracy.

Key words: roller-hemming forming, SPH-FEM coupled, aluminum alloy sheet, adhesive

CLC Number:

TG156

LI Jianjun, ZHU Wenfeng. Numerical Simulation and Experiment of Roller Hemming-compression with Flat Surface-curved Edge Aluminum Alloy Sheet Based on SPH[J]. Journal of Mechanical Engineering, 2020, 56(24): 61-71.

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