Trimming Line Design of Auto-body Panel with Complex Shape Using Finite Element Inverse Method

Trimming line design plays an important role in obtaining accurate edge profile after flanging. Compared to the traditional section-based method, simulation-based method can produce more accurate trimming line by considering deformation mechanics. Recently, the use of a finite element inverse method is proposed to obtain optimal trimming line. By analyzing flanging inversely from the final mesh after flanging, trimming line can be obtained from initial mesh on the drawing die surface. Initial guess generation fer finite element inverse method is obtained by developing the final mesh onto drawing tool mesh. Incremental development method is adopted to handle irregular mesh with various size and undercut. In this study, improved incremental development algorithm to handle complex shape is suggested. When developing the final mesh layer by layer, the algorithm which can define the development sequence and the position of developing nodes is thoroughly described. Flanging of front fender is analyzed to demonstrate the effectiveness of the present method. By using section-based trimming line and simulation-based trimming line, incremental finite element simulations are carried out. In comparison with experiment, it is clearly shown that the present method yields more accurate edge profile than section-based method.