Tool and process design for progressive forming of an automotive bracket part using finite element analysis.

This paper deals with the design procedure of the tool and process for automotive bracket part fabrication. Finite element analysis is introduced to the progressive process to investigate the causes of defects that occur during the forming and bending stages. This paper proposes a new guideline for the progressive process design that modifies the intermediate stages in the progressive process. Finite element analysis and pilot tests are performed again using new strip layout and tool shapes to confirm the validity of the proposed process design. The analysis result shows that the modified process design eliminates defects such as non-uniform thickness distribution and initiation of crack. Then, the automotive bracket part is successfully fabricated through pilot tests using the progressive tools designed in accordance with the proposed guideline. [ABSTRACT FROM AUTHOR]