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JournalofMaterialsProcessingTechnology101(2000)31±43

Optimumblankdesignofanautomobilesub-frame

aa,*b

Jong-YopKim,NaksooKim,Man-SungHuh

aDepartmentofMechanicalEngineering,SogangUniversity,Shinsu-dong1,Mapo-ku,Seoul121-742,SouthKorea

bHwa-shinCorporation,Young-chun,Kyung-buk,770-140,SouthKorea

Received17July1998

Abstract

Aroll-backmethodisproposedtopredicttheoptimuminitialblankshapeinthesheetmetalformingprocess.Themethodtakesthe

differencebetweenthe®naldeformedshapeandthetargetcontourshapeintoaccount.Basedonthemethod,acomputerprogram

composedofablankdesignmodule,anFE-analysisprogramandameshgenerationmoduleisdeveloped.Theroll-backmethodisapplied

tothedrawingofasquarecupwiththe¯angeofuniformsizearounditsperiphery,tocon®rmitsvalidity.Goodagreementisrecognized

betweenthenumericalresultsandthepublishedresultsforinitialblankshapeandthicknessstraindistribution.Theoptimumblankshapes

fortwopartsofanautomobilesub-framearedesigned.Boththethicknessdistributionandthelevelofpunchloadareimprovedwiththe

designedblank.Also,themethodisappliedtodesigntheweldlineinatailor-weldedblank.Itisconcludedthattheroll-backmethodisan

effectiveandconvenientmethodforanoptimumblankshapedesign.#2000ElsevierScienceS.A.Allrightsreserved.

Keywords:Blankdesign;Sheetmetalforming;Finiteelementmethod;Roll-backmethod

1.Introductiontheslip-line®eld-methodwiththeassumptionofplane-

strain¯angedeformation.Also,Jimma[2]andKarima

Itisimportanttodeterminetheoptimumblankshapeofa[