International Journal of Recent Advances in Multidisciplinary Topics 194

Volume 2, Issue 4, April 2021

https://www.ijramt.com | ISSN (Online): 2582-7839

Design and Forming Analysis of BIW Sheet

Metal Component Using Autoform Simulation
Software
Rahul Taware1*, Vidyadhar Rajmane2
1,2
Department of Mechanical Engineering, Shivnagar Vidhya Prasarak Mandal College of Engineering,
Baramati, India

Abstract: BIW is a frame member of a vehicle, which forms the Production tool. The correct software tool will depend on both
chassis of vehicle. It has so many small features with ups and the application and the stage of product development. Design
downs. The component is manufactured by draw type die. This is of sheet metal forming is traditionally relying on the experience
because to reduce the draw depth and it has two rows of draw
beads. It seems to be difficult to form due to their small radius accumulated by tool design engineers through long and costly
fillets. In this analysis, there is a need to find out the forming trial and error experiments. Simple empirical methods provide
feasibility of this component and if not possible in single stage then some guidelines for cases similar to those on which these
we need to modify the die design with least modification and need methods were developed. In increasing number of cases with
to optimize the draw bead profile and draw radius in such a way complex geometry's and thinner stronger materials,
that we can get the good component in a single stage itself. For thin experiments are used extensively consuming time and money
and very big forming dies, we need to do gravity analysis. If our
die face is profiled one, then we may need to do binder wrap before providing a workable solution. These experiments
analysis. The component wrap analysis results are taken to the usually lead to one severity conclusion (the pressed part fails or
forming analysis. After the forming analysis, if trimming is there not) with little if any information on the safety margin. The
means just before trimming analysis we have to do mesh arising need to produce more complex parts in the most
Coarsening. Then the coarsened mesh and its results are taken for economical way calls for a tool design methodology capable of
trimming analysis. The results of the trimming analysis are taken providing the engineer with a more detailed insight of the
to the spring back analysis. From the results of the spring back
analysis, further we can cross check the spring back of the real physical behavior. This applies especially for parts made of new
component. The analysis results obtained is used in sheet metal materials for which experience lacks another strain on the
industry for metal forming process. overall design cycle of a new product in the Traditional
approach results from the fact that before prototypes for testing
Keywords: Analysis, Draw Die, Forming Die, Tonnage, etc. can be manufactured a whole series of preliminary tasks must
be carried out (sequential engineering). The target of a 'fast-to-
1. Introduction the market' release of new products ideally requires a
The use of simulation software in metal forming process has simultaneous engineering approach in which the assessment of
increased significantly in recent years as the benefit of manufacturability can be explored as early as possible in the
troubleshooting and optimizing process on the computer rather design cycle. These emerging needs called for a new tool design
than through extensive shop floor trials have been realized. The methodology based on numerical simulation. The new CAE
rapid development of software technology, together with faster methodology investigates and simulates the physical
and lower cost computer hardware, has recently enabled many phenomena developing during sheet metal forming. This is
manufacturing operations to be modeled cost-effectively that achieved by using a numerical simulation tool – AUTO FORM,
only a few years ago would have been considered impractical. HYPER FORM, L.S –DYNA, DYNAFORM, PAM-STAMP
Many of these advances have been made possible by tailoring etc. - which is used throughout a multistep design process-
and optimizing programs for specific applications, which has formability evaluation with numerical simulation (FENS) [1-2].
resulted in the general terms of “sheet forming” and “bulk This approach provides the design engineers with a detailed
forming” applied to different types of process modeling insight or what is happening in sheet metal forming and which
software [8-10]. For examples, sheet metal forming is currently are the causes of troubles, thus easing their solutions. Sheet
developing much interest in the globe as a means of reducing metals parts have the advantage that the material has a high
both the development cost of stamping a new part and the elastic modulus and high yield strength so that the parts
production lead-time. These costs are accumulated over the produced can be stiff and have a good strength-to- weight ratio.
entire development process from initial part design to the final A large number of techniques are used to make sheet metal

*Corresponding author: [email protected]

R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 195

parts. Spring back effect is important in forming processes [3].

Fig. 2. Inside and outside bends in a channel section

2. Theory
Fig. 1. Magnified section of blanking a sheet showing plastic deformation The stamping product cycle involves sheet metal forming
and cracking
operations. The forming operation leads to induced residual
As sheet is usually delivered in large coils, the first operation stresses. There are chances of split, wrinkle and thinning on
is to cut the blanks that will be fed into the presses; subsequently panel by residual stresses. The problem arises due to the split,
there may be further blanking to trim off excess material and wrinkle, thinning, which directly affect the formability of
pierce holes. The basic cutting process is shown in Figure 1. component and results obtained are out of acceptability limit In
When examined in detail, it is seen that blanking is a this paper design and analyze of BIW component by using Auto
complicated process of plastic shearing and fracture and that the form Simulation software and design die and punch forming
material at the edge is likely to become hardened locally. These surfaces for defect free part using CATIA V5 is discussed. The
effects may cause difficulty in subsequent operations and appropriate capacity press can be selected by knowing the
information on tooling design to reduce problems can be found drawing load. Working with the presses of higher capacities
in the appropriate texts. may lead to many types of defects such as cracks and tearing.
Blank holder pressure needs to optimize over a given range for
A. Bending optimized geometry. The coefficient of friction needs to be
The simplest forming process is making a straight line bend. optimized for the new geometry. Generally the deep drawing
Plastic deformation occurs only in the bend region and the objects are analyzed for their strength and failures with circle
material away from the bend is not deformed. If the material grid analysis, which is practically carried out on a sample piece,
lacks ductility, cracking may appear on the outside bend which is known as formability analysis. Alternatively, the
surface, but the greatest difficulty is usually to obtain an actual trials performed over the component would directly
accurate and repeatable bend angle. Elastic spring back is reflect over the ease of `drawing operation’ offered for the said
appreciable [13-14]. Die design.
In roll forming machines, there are a number of sets of rolls
that incrementally bend the sheet, and wide panels such as 3. Design of BIW Component
roofing sheet or complicated Clamp die Fracture channel
A. Engine Mounting Bracket
sections can be made in this process. A technique for bending
at the edge of a stamped part is flanging or wiping as shown in Engine mounts have an important function of containing
Figure. The part is clamped on the left-hand side and the firmly the power-train components of a vehicle. Correct
flanging tool moves downwards to form the bend. Similar geometry and positioning of the mount brackets on the chassis
tooling is used is successive processes to bend the sheet back ensures a good ride quality and performance. As an FSAE car
on itself to form a hem. If the bend is not along a straight line, intends to be a high performance vehicle, the brackets on the
or the sheet is not flat, plastic deformation occurs not only at frame that support the engine undergo high static and dynamic
the bend, but also in the adjoining sheet. If the part is curved stresses as well as huge amount of vibrations. Hence,
near the flange or if both the flange and the part are curved, as dissipating the vibrational energy and keeping the stresses
in figure, the flange may be either stretched or compressed and under a predetermined level of safety should be achieved by
some geometric analysis is needed to determine this. careful designing and analysis of the mount brackets. Keeping
this in mind the current paper discusses the modeling, Finite
B. Section Bending Element Analysis, Modal analysis and mass optimization of
In Figure 2, a more complicated shape is bent. At the left- engine mount brackets for a FSAE car. As the brackets tend to
hand end of the part, the flange of the channel is stretched and undergo continuous vibrations and varying stresses, the fatigue
may split, and the height of the leg, h, will decrease. When the strength and durability calculations also have been done to
flange is on the inside, as on the right, wrinkling is possible and ensure engine safety.
the flange height will increase.
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 196

than the other materials in the list.

Bending Force Calculations
Cutting force calculation:
Shear strength (N/mm2 ) = 455 N/mm2
Cuttingforce = Perimeter of part (mm) ×
Thickness of part (mm) × Shear strength (N/mm2 )
= 512.3 × 6 × 455 = 1398579 N
= 1398.579 KN
= 142.56 TONNES
Bending force calculations:
Assuming bending force 80% of cutting force.
Fig. 3. 3D View of Component 142.56 x 70
Therefore Bending Force =
100
B. Part Significance Bending Force = 99.79 Tonnes
Table 1 Part significance Therefore, bending force for 1 single part is 100 tonnes.
Drawing/Part No. 2855 2620 8211 Similarly, for 2 parts bending force will be,
Drawing/Part Designation BRACKET (TRUCK) Bending Force = 2 x 99.79
Material Thickness 6 mm Thickness
Bending Force = 199.58 Tonnes
Material Specification HR-E 46 (BSK-46)
Envelope Dimensions (mm) 188.31 x 224.11 x 247.0 Here consider joining part off material 10%
199.58 ×10
Final mass in kg. 2.948 kg. Then, Bending Force at joint =
Customer Name TATA MOTORS 100
LIMITED ERC - PUNE = 19.95 Tonnes
Therefore, Total Bending Force = Bending Force for two
1) Part Drawing parts + Bending force at joint
= 199.58 + 19.95
= 219.53 Tonnes
Hence total Bending force for Engine Mounting Bracket is
219.53 Tonnes.
D. Blanking Tool Calculations
1) Cutting Clearance for Blanking Tool
Fig. 4. Front view Cutting Clearance for 6 mm BSK – 46 material is calculated
as follows; For 6 mm thick material, Cutting Clearance (both
side) = 15% of thickness (From standard chart) = 0.15 x 6
=0.9mm. Therefore cutting clearance for Die is 0.9 mm for both
side i.e. 0.45 mm per side clearance. OP50
2) Actual Tonnage Calculation for Blanking Tool Material
thickness = 6 mm
Total Perimeter of Blank (mm) = 1207.1 mm (From CAD
model)
Shear strength (N/mm2 ) = 455 N/mm2
Fig. 5. Top view Cuttingforce = Perimeter of part (mm) ×
Fig 4 and fig 5 shows front nad top view of component. Thickness of part (mm) × Shear strength (N/mm2 )
= 1058.3 × 6 × 455 = 2889159N
C. Material Properties of BSK-46 2889.159
BSK- BIG STEEL KEG Tank type geometry used in auto = KG
9.81
component. (BSK 46)- can be produced by controlled cooling = 294.51 TONNES
after hot rolling, has composition as under: F = 294.51 Tonnes ≤ 300 Tonnes
Carbon Equivalent (CE):- 0.41 Max Therefore, Schuler - 300T Press is selected for Blanking tool.
WHERE, C.E.=(C+(Mn/6)+((Cr+Mo+V)/5)+ ((Cu+Ni)/15))
Trace elements other than specified should not exceed 0.2% in 4. Simulation of BIW Component
total by weight Tooling sequence for Engine mounting bracket has major
 Material Tensile strength – 500-640 MPa influence on part forming. Therefore we considered following
 Yield strength – 460-560 MPa tool sequence for bracket.
 Poison Ratio - 0.31
 Young's Modulus - 210 GPa.
It is clear from the properties of materials mentioned in
table1, that BSK 46 has more tensile, yield and modulus value
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 197

Table. 2 Operation sequence

Fig. 7. Forming-1 Tool setup

The process is considered "deep" drawing when the depth of

OP05 – Blanking Tool the drawn part exceeds its diameter. This is achieved by
A blanking die produces a flat piece of material by cutting redrawing the part through a series of dies. The flange region
the desired shape in one operation. The finished part is referred (sheet metal in the die shoulder area) experiences a radial
to as a blank. Generally a blanking die may only cut the outside drawing stress and a tangential compressive stress due to the
contour of a part, often used for parts with no internal features. material retention property. These compressive stresses (hoop
It is not practically possible to manufacture single part in stresses) result in flange wrinkles (wrinkles of the first order).
forming therefore we have taken two parts as per feasibility of Wrinkles can be prevented by using a blank holder, the function
manufacturing for Engine mounting bracket. If we take single of which is to facilitate controlled material flow into the die
part in forming (draw) die it will cause failure of part. radius.
B. OP20 – Forming-2 Tool

Fig. 8. Forming-2 Tool setup

Part is partially formed in Forming Tool-1, and its final shape

is formed in second forming tool. The setup for OP20-Forming
Tool is as shown in fig. In forming tool-2 part is situated upside
Fig. 6. Development blank in autoform software
down as shown in fig. 8. This upside down position of part is
Fig. 6 shows blank developed by Autoform software. preferable for ejection. Forming tool-2 consist of ejection pad
Autoform software interface requires 3D stp file or igs file for in upper assembly of die. Upper pad is movable part and its
capturing surface of part. After it convert it into development movement is controlled by cution pins of press bed. Firstly pad
blank. In Engine mounting bracket as we considered two part holds the part in the start of operation in position, and similarly
for balance forming, it gives us above development blank. at end of operation i.e. after hitting the part it eject the part.

A. OP10 – Forming-1 Tool C. OP-30 Piercing (6 Station) & Cam Piercing (2 Station)
In Engine mounting bracket it is not practically feasible to 1) Before Piercing
obtain final part in single forming tool, therefore we have
considered two forming operations Forming-1 tool and
Forming-2 tool. Deep drawing operation is a sheet metal
forming process in which a sheet metal blank is radially drawn
into a forming die by the mechanical action of a punch. It is thus
a shape transformation process with material retention.
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 198

2) After Piercing 1) Before Pierce and Part –off

Fig. 9. Pricing tool setup

2) After Piercing and Part off
P-30 is cutting tool which consist of two stations, one vertical
piercing and another horizontal cam piercing. Vertical piercing
done at 6 positions and horizontal cam piercing at two positions
as shown in fig. 11. Station-1 consist of six piercing holes of
11mm diameter and punching is done by vertical punch.
Station-2 consist of two whole piercing of 12mm diameter. At
station-2 horn piercing done by two cam which are opposite to
each other
Fig. 11. Top Windo Cut & Cam Pie (2 Station)
D. OP-40 Top Windo Cut & Cam Pie (2 Station)
Op-40 consist of two stations, top window cutting and Cam 5. Manufacturing and Testing
piercing, The shape of this top window cannot be defined in After deciding Operational sequence, tools has been
blanking die before forming predations as it get stretched in in designed as per sequence. Designing of press tools has done by
forming, therefore it had done after forming the parts. Top CATIA V5 R26 as per manufacturing feasibility. After
window cutting done as per final part dimension required. At designing DAP (Design Approval Process) has been done with
station-2 second hole of 10 mm diameter is pierced by two customer. DAP is most important in tool designing and it cannot
cams, which are positioned opposite to each other. As we can go ahead without customer DAP. After approving we released
see in drawing there is only 17.5 mm center distance in part manufacturing 3D and 2D on shop floor.
flange, therefore it is not feasible to pierce both holes in same
cutting tool.

1) Before Piercing

Fig. 12. NC Programming in Delcam

3D model from CATIA V5 cannot be machined as it in the

“.catpart/.cat product format, therefore it needs to be converted
2) After piercing into stp file format. Step file format is readable with any 3D
CAD or CAM software. Manufacturing programming of tool’s
parts has done using Delcam software, and program has given
to Numerical control of VMC (Vertical Machining Centre)
machine. Machining of model is always done with tool which
is selected in programing. After machining parts are assembled
in two main assemblies i.e. Upper assembly and Lower
assembly. After matching punch and die block are sent outside
Fig. 10. Top Windo Cut & Cam Pie (2 Station) for vacuum hardening. Punch and die block are always
E. OP-50 Part Off and Piercing hardened in the range of 60-65 HRC (Hardness Rockwell
Part off and piercing is two station die, which pierce 6 holes Constant). After assembling final inspection of tools has done.
of 11 mm diameter at first station. And at second station it part Then it is taken in press shop for trial.
off into two separate two parts. Part off operation done
simultaneously with the help of two separate punches and die
sets.
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 199

A. Testing of Blanking Tool parameters of the model must describe the real process as
1) Lower Assembly accurately as possible so that the results of the simulation are
realistic. The metal forming simulation enables fast and
accurate simulation of the entire forming process including
drawing and secondary operations as well as spring back. In this
way, the part can be developed completely and efficiently. The
typical parameters for forming simulation are, for example, part
and tool geometry, material properties, press forces and friction.
The simulation calculates stresses and strains during the
forming process. In addition, simulations allow for the
recognition of errors and problems (e.g. wrinkles or splits) as
2) Upper Assembly well as results (e.g. strength and material thinning). Even spring
back, the elastic behavior of material after forming, can be
predicted in advance. Forming simulation also provides
valuable information about the influence of process variations
on stamping robustness.
A. Software Result: OP-10 Forming-1 Tool
1) Thinning
Fig. 13. CAD Model of OP05 – Blanking Tool Maximum thickness is +0.175 which is occurred at flange
side of part. Minimum material thickness is -0.187 which is
observed at deep draw section of part as shown in fig. below.

2) Formability
Fig. 14. Actual Blank – Product of Blanking Tool Fig shows formability analysis of component, it is observed
component is supposed to thicken at the radius portion
Tryout is the step in the engineering and manufacturing
simultaneously it tends to compression at the middle of flange.
process of a tool when the tool is first loaded into the press in
an initial attempt to produce a part. Next, the tool undergoes
extensive fine tuning during tryout, which is a cost and time
intensive step on the path to the successful production of quality
tool. As correctional work and modifications are inevitable,
every correction loop that can be avoided offers an immediate
advantage in terms of time and money. However there are
always some variation in part dimension in forming tools. The
Try-out team must carry out several correction loops on the tool
until the tool can be used to produce a part of the required Fig. 15. Analysis of sheet metal using Autoform CAE Software
quality.
3) Wrinkles
Fig shows wrinkle analysis of forming – 1 tool. There is only
6. Results and Discussion
one portion where forming of wrinkle occurs, at the joint of two
In metal forming simulation, the forming of sheet metal is parts in the component as we can see in the fig. The maximum
simulated on the computer with the help of special software. magnitude of wrinkles is 0.21 mm, however it doesn’t affect the
Simulation makes it possible to detect errors and problems, component as its scrap in part off tool.
such as wrinkles or splits in parts, on the computer at an early
stage in forming. In this way, it is not necessary to produce real
tools to run practical tests. Forming simulation has become
established in the automotive industry since it is used to develop
and optimize every sheet metal part. To illustrate the metal
forming process, there must be a model of the real process. This
is calculated in the software using the finite element method
based on implicit or explicit incremental techniques. The
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 200

4) Spring back
In forming tool 1, there is more spring back effect in outer
edge of the part as shown in below fig. At inner cut out section
it is -1.095 i.e negative therefore it tends to vibration.

D. OP-40 Top Window Cut and Cam Piercing

1) Spring back
In top window cutting operation maximum spring back is
+0.206 which is observed at outer edge of flange and minimum
B. OP-20 Forming-2 Tool spring back is -0.732 at upper wall of part as it is held in position
1) Thinning by stripper plate. The force required in window cutting
In forming-2 tool maximum thinning occurs at the flange of operation is large as compared other piercing operation as it
the component as shown in the fig. As compared to formong-1 cutting perimeter is large than others.
tool thinning is less in forming-2 tool.

2) OP Part Off and Piercing

2) Formability Spring back effect in part off tool is shown in figure below.
Figure shows formability analysis of Forming-2 Tool. The maximum spring back effect is + 0.070 which found at
Thickening of component continues till the end of forming-2 extreme point on lower side of flange and minimum spring back
tool at the side flange as shown in figure. There is no any excess is – 0.223 which found at upper wall near cutting edge of
thinning observed at the job. component. However spring back effect in in part of tool is
3) Wrinkles small as compared to other tools.
In forming-2 tool wrinkles are observed at two portions, at
the joint of two parts which are formed in forming-1 tool and at E. Forces Developed
the concave shaped flange as shown in fig. 1) In Forming-1 Tool
4) Spring back The forces developed in upper, lower die and pad assembly
of Forming-1 tool of the BIW component is as follows

Spring back analysis of forming-2 tool is as shown in fig. Its

Fig. 16. Forces Developed In Forming-1 Tool
magnitude is higher at extreme point on flange of component.
Higher magnitude observed of spring back effect in the 2) In Forming-1 Tool
component is +1.674. Similarly minimum magnitude of spring The forces developed in upper, lower die and pad assembly
back effect is observed of -0.601 at internal cutout section as of Forming-2 tool of the BIW component is as follows
showed in figure below.
C. OP-30 Piercing 6 Stations & Cam Pierce
1) Spring back
Spring back effect is also observed in Piercing 6 station and
cam piercing die. The maximum magnitude of springbuck is
observed at horizontal cam piercing hole of +0.029. There is
also medium spring back effect observed at middle cross holes.
Fig. 17. Forces Developed In Forming-2 Tool
R. Taware et al. International Journal of Recent Advances in Multidisciplinary Topics, VOL. 2, NO. 4, APRIL 2021 201

7. Conclusion [8] Dae Up Kim, Young Choi, Bong Yong Kang, “A Study on Process Design
of Automobile Parts Using Extruded Material by Die Forming” Hindawi
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