Shanghai Jiaotong Daxue xuebao (Apr 2022)
Modeling and Experiment on Roll-Hemming Forming Process of Aluminum Alloy Sheet with Adhesive
Abstract
In the roll-hemming forming process of door cover, the non-metallic flanging adhesive and the interaction between light metal and flanging adhesive will affect the manufacturing accuracy and performance of the door cover, and increase the difficulty of roll-hemming forming and quality control of automobile body sheet with adhesive. Therefore, a numerical analysis model for roll-hemming forming of aluminum alloy sheet with adhesive was proposed based on the finite element method and the smooth particle hydrodynamic (FEM-SPH) method. First, SPH was used to simulate the extrusion flow process of the flanging adhesive, and a roll-hemming simulation model of sheet metal with adhesive was established in combination with FEM. Then, an experimental platform for two-pass roll-hemming forming of aluminum alloy sheet with adhesive was built, and the roll-hemming loss and surface wave coefficient were taken as the roll-hemming forming quality index to analysis and verify the validity of the numerical model. After that, the quality change between the first pass and the last pass and the key process parameters affecting quality were studied based on the orthogonal test method. Finally, the fitting relationship between roll-hemming forming quality and process parameters was established. The results show that the roll-hemming loss and the surface wave coefficient of the last pass are reduced compared with the first pass. The process parameters that affect the surface wave coefficient in descending order are flanging height, fillet radius, TCP-RTP value, and roller diameter. The process parameters that affect the roll-hemming loss in descending order are TCP-RTP value, fillet radius, flanging height, and roller diameter. The fitting relationship can support the prediction of roll-hemming forming quality of aluminum alloy sheet with adhesive.
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