Experimental study of surface defects on automotive doors during flanging and their numerical prediction

A. Le Port^1,2, S. Thuillier^1,2, P.Y. Manach^1,2a and J. Garabed³

¹ Université de Bretagne-Sud, LIMATB, rue de Saint Maudé, BP 92116, 56321 Lorient, France
² Université européenne de Bretagne, France
³ PSA Peugeot Citröen, DTI/DITV/ICPE/CEMB, BP 95217, F-35652 Le Rheu, France

^a e-mail: pierre-yves.manach@univ-ubs.fr

Published online: 10 June 2010

Abstract

Surface defects can develop on automotive exterior panels after drawing and flanging steps, during springback and may alter significantly the vehicle quality. These defects are characterized by a depth below 0.5 mm and are then difficult to detect or predict numerically. This study focuses on a L-shaped part designed on purpose to reproduce at a small scale surface defects that occur after flanging. Dimensions of these defects are measured from profiles obtained with a tridimensional measuring machine. The investigation of the influence of the flanging height and flanging speed shows than neither of these parameters have impact on the surface defect . The numerical simulation of the flanging process predict the surface defect but with a lower depth than the experimental defect.