Finite Element Simulation of High-Speed Blow Forming of an Automotive Component

Abstract

High-speed blow forming (HSBF) is a new technology for producing components with complex geometries made of high strength aluminum alloy sheets. HSBF is considered a hybrid-superplastic forming method, which combines crash forming and gas blow forming. Due to its novelty, optimization of the deformation process parameters is essential. In this study, using the finite element (FE) code ABAQUS, thinning of an aluminum component produced by HSBF under different strain rates was investigated. The impact of element size, variation of friction coefficient, and material constitutive model on thinning predictions were determined and quantified. The performance of the FE simulations was validated through forming of industrial size parts with a complex geometry for the three investigated strain rates. The results indicated that the predictions are sensitive to the element size and the coefficient of friction. Remarkably, compared to a conventional power law model, the variable m-value viscoplastic (VmV) model could precisely predict the thickness variation of the industrial size component.