Development of Technology for Manufacturing Facing Panels by Universal Die Tooling

Abstract

The paper describes sheet stamping’s technological process, which includes the process of drawing outer body panels of low-carbon structural steel and low-carbon stainless steel by multi-purpose die tooling. The characteristics of the materials differ significantly, which means that the shaping process proceeds with significant differences. It should be noted that stainless steel billets are stamped with polyethylene. Using a polyethylene film allows you to eliminate surface defects on the outer body panels, but this technique leads to a change in the friction coefficient. A significant difference in the characteristics of blank materials leads to the need to find compromise engineering solutions. The AutoForm software package serves as a tool for automating the design of the stamping process in terms of optimizing technological parameters. The software product allows you to simulate the process of drawing a sheet blank, determine the “problem” area or elements on the part, and select the geometry and friction parameters of the tooling, as well as the necessary power characteristics for the machinery. For the part under consideration, the “problem” element was the inner radius along the contour of the part, which is equal to the thickness of the product material. The purpose of the study is to select the minimum allowable radius at which it would be possible to obtain a suitable product on one unit of tools and equipment and ensure that the equipment can operate in automatic mode.

When analyzing the results of computer modeling and experiment, it was determined that the minimum possible radius on the part’s inner surface for products made of low-carbon structural steel should be equal to at least one thickness of the initial billet. For products made of low-carbon stainless steel, it should be equal to at least two thicknesses of the initial blank. The radius at the corners of low box products on the blank’s inner surface must be equal to at least three thicknesses of the original blank. To improve die tooling’s technical characteristics, it is necessary to use technologies of nanostructured PVD coatings.