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Research on automatic analysis and layout system of the stamping process for automotive panels and its key technologies

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Abstract

With the shorter update cycle of automobiles and the development trend of fashion and streamlined appearance, the design of forming processes is becoming increasingly complex and demanding, and a large number of composite processes need to be used and arranged in 2–5 procedures to reduce production costs and shorten production cycles, which is usually done by trial and error. Aiming at the automatic recognition, analysis, and layout of process features, an intelligent system based on the computer-aided geometric design (CAGD) theory of complex curves and surfaces, process design knowledge, and multidisciplinary optimization techniques is proposed. The process feature analysis method based on discretization and merging idea has been proposed to split big and complex geometric form features and identify every process feature accurately and automatically, such as piercing, trimming, flanging, restriking, and its punching directions. The combinatorial optimization algorithm is proposed to merge the discrete features according to the best stamping direction, process rules, and the geometric parameters of the features, and a process constraint diagram with combined features is constructed, which is used as the initial solution and sequence constraint conditions for the process layout to effectively ensure the rationality of the process layout. Moreover, based on the die design rules, the simplified tools of the process features are created, and a rapid interference detection algorithm of the tools is proposed to realize the automatic layout and optimization of the stamping process to reduce the number of process steps as much as possible. Finally, the aforementioned algorithms are seamlessly integrated into the NX software to develop an automatic analysis and layout system. Case studies and industrial applications have shown the system’s strong capabilities in process analysis and layout of automotive panels, which can significantly improve design efficiency.

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Acknowledgements

We express our thanks to Renping Luo, Huping Sun, Yan Wang, and Jing Gao from General Motors’ stamping department for their great supports during the research.

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Authors and Affiliations

  1. National Engineering Research Center of Die & Mold CAD, Shanghai Jiao Tong University, Shanghai, 200030, China

    Chuipin Kong, Jialin Lei, Jiale Chao & Xiong Hui Zhou

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  1. Chuipin Kong
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All authors have contributed to the conceptualization and design of this study. All authors have read and approved this manuscript.

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Correspondence to Xiong Hui Zhou.

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Kong, C., Lei, J., Chao, J. et al. Research on automatic analysis and layout system of the stamping process for automotive panels and its key technologies. Int J Adv Manuf Technol 129, 4101–4120 (2023). https://doi.org/10.1007/s00170-023-12540-5

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  • DOI: https://doi.org/10.1007/s00170-023-12540-5

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