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Effect of Geometry, Material and Blank Holder Force on Formability of BIW parts

Mrugank Dilip Jaisingkar, Shantanu Vyankatesh Naidu, Dr Gaurang Shah


The major constituent of any car body consists of about 400 sheet metal stamped parts. Geometry and material of these parts is not uniform. In order to design these parts for any car, it is essential to know how these parts are manufactured. During our study of the manufacturing processes of these parts, we found that the part designs are repeatedly sent back to the body design team for change in geometry, material or both. This re-iteration of design is extremely time consuming and affects the overall launch time severely. Our efforts focussed on studying the most frequently occurring defects like wrinkles, splits, thinning etc. and provide early solutions so that there will be no delay in product launch. This process is known as Design for Manufacturing and it focusses on the need of practical knowledge of formability which is a requirement of every BIW designer. This paper also provides solutions to the most frequent formability defects being faced during manufacturing.

Keywords: BIW, DFM, FLD, forming defects, early simulation


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