Simulating the Complete Forming Sequence for （模拟的完整形成序列）.pdfVIP

6th European LS-DYNA Users’ Conference Simulating the Complete Forming Sequence for a Roll Formed Automotive Bumper Beam Authors: Trevor Dutton, Paul Richardson Dutton Simulation Ltd Matt Tomlin, Tom Harrison Wagon Automotive plc Correspondence: Trevor Dutton Dutton Simulation Ltd Phone +44 1926 732147 Fax +44 1926 732147 Email trevor.dutton@ ABSTRACT: As part of the development of a new automotive bumper beam, a complete simulation of the entire forming process was carried out using LS-DYNA. The material for the beam was an ultra high strength steel presenting many challenges for the forming process. The sequence of forming operations was roll-forming (including forming a sweep in the initially straight roll-formed section), local annealing, forming of an initiator in the wall of the section and then crushing the end of the previously rolled section. The forming results (geometry, thinning and work hardening) were all transferred to the simulation of the bumper performance under various impact conditions. The paper describes the development of certain novel simulation techniques, particularly for the roll-forming for which the implicit analysis options of LS-DYNA were used, representation of the annealing process, as well as the method in which data was transferred between the various