Effects of process parameters on the deformation energy in a sheet-bulk metal forming process for an automotive component

The present study investigates the effects of the process parameters on cold forming process of an automotive component in AISI 1006 low carbon steel. The material formability was characterised up to 250°C. The material flow behaviour and the related thermal distributions during the geometrical transformations were analyzed. Coining and forming operations were investigated by using a coupled 3D Thermo-mechanical FEM with different die geometries and friction conditions in order to optimize the final die geometry and to reduce the energy consumption. FEM simulation results were validated by comparison with the experimental trials. The detailed study of the component allowed defining the energy required by the severe bending of the initial thick plate. The FEM predictions led to a reduction of deformation energy of about 20%, a mass reduction of 28% on the final product and permitted avoiding secondary machining operations.