FEM analysis and design bulb shield progressive draw die.pdf

Af d t a S t ? K 1 t d c w f i ( s h t c c d w w t m s s 0 dJournal of Materials Processing Technology 189 (2007) 58–64 FEM analysis and design bulb shield progressive draw die Z.Q. Sheng ?, R. Taylor, M. Strazzanti Isatec Technical Center, 5353 W 161st St., Cleveland, OH 44142, USA Received 4 August 2006; received in revised form 5 January 2007; accepted 9 January 2007 bstract Bulb shields are important components in the automobile headlamps and are primarily manufactured by progressive draw dies. Among progressive orming, multiple station progressive draw dies are the most formidable and thus among the most difficult of all progressive dies. Draw processes of a ome shape bulb shield are modeled and analyzed by FEM code DYNAFORM v5.2. Simulation prediction matches well with the measurement from he prototype test. A surface distortion problem is also identified and a solution is obtained through punch nose radius effect on stress distribution nalysis. The tooling based on the suggested design has been manufactured and is running successfully in a Cleveland based production plant. ince the forming problems can be visually identified before physical tooling is manufactured, compared with the traditional development, the ooling tryout time has been shortened from several weeks to several days. 2007 Elsevier B.V. All rights reserved. ; Sur s t b a u s b l t d t e ( r c r seywords: Progressive drawing; Incremental FEM; One-step FEM; Bulb shield . Introduction Headlamps are critical to vehicles in two aspects: (1) the aes- hetics of a headlamp is important as it affects vehicles’ styling esign; (2) the quality of generated light beams affects vehi- le safety, e.g. a too strong beams distract oncoming drivers hile weak light beam will cause reduced seeing performance or the driver. The bulb shield, which is made from sheet metal, s mounted in front of the bulb and prevents unwanted light glare light) to exit the headlamp. Thus, the quality of the bulb hield directly affe