판재 성형해석을 활용한 자동차 BRKT-FENDER MTG 부품 고효율 프레스금형 개발에 관한 연구

Abstract

This study applies simultaneous engineering processes in the automotive parts manufacturing industry to create detailed virtual models of assemblies, sub-assemblies, or components intended for production. It emphasizes the critical role of computer-aided engineering (CAE) as a crucial tool for calculating and evaluating product formability through virtual test production, focusing on the development and optimization of press dies. The primary goal of this research is to extensively utilize 3D CAD models to enhance the efficiency of stamping and forming processes for automotive parts, thereby reducing die manufacturing costs and product production costs while ensuring the quality of the final product. Specifically, the research reveals that by developing the innovative forming method for the BRKT-FENDER MTG, a functional automotive component, instead of using the traditional drawing method, raw material savings reached 43.89%. Assuming a production volume of 300,000 hits (based on typical die lifespan), approximately $120,700 in savings was achieved, and die manufacturing costs for OP10 showed a potential cost reduction of 16-24%. The study concludes that utilizing precise sheet metal forming analysis programs for virtual simulations from the early stages of die development allows for the integration of various process parameters, helping predict and prevent potential issues during the manufacturing process. This approach aids in achieving profitability in automotive parts production and die development.