Case Analysis of Automobile Sheet Metal Stampings

Most automotive sheet metal parts are produced using cold stamping. In real-world manufacturing, these stamped components often suffer from various defects such as wrinkles, material stacking, necking, springback, trimming issues, burrs, crushing, and slip lines. Among these, part stacking can lead to scrap, affecting both quality and production efficiency. Drawing on my professional experience, I will analyze the causes of these defects and present solutions for improving the quality of automotive sheet metal stampings. Li Likun, from the Technical Center of SAIC-GM-Wuling Automobile Co., Ltd., has extensive experience in solving common stamping issues. After the forming process is completed, the original state of a car body panel shows a stacking defect in the red-circled area. These areas are critical for assembly with other parts, and excessive material accumulation significantly reduces the size of the body-in-white, leading to fitment problems. One of the main reasons for this issue is related to the design of the part's features. The product design in the stacking area encourages material gathering during the stamping process. If the material flow is not controlled effectively, it leads to stacking defects. To address this, we first focused on optimizing the part’s geometry. We introduced a rib in each stacking area of the improved digital model. These ribs help to spread out the gathered material, thereby reducing the stacking problem. However, adding ribs requires careful consideration. On one hand, they must not cause interference between parts. On the other hand, their height must be limited to avoid weakening the punch strength. As a result, the improvement in stacking is somewhat constrained due to these design limitations. In addition to modifying the part design, we also optimized the stamping process. Since increasing the rib height had limited effectiveness, we turned our attention to adjusting the stamping direction. By selecting an appropriate punching direction during the forming process, we were able to better control the material flow in the stacking area, which significantly reduced the occurrence of stacking defects. This improvement was achieved by carefully analyzing the material behavior during stamping and making adjustments that enhanced the overall performance of the process. The results showed a clear reduction in stacking, demonstrating the importance of combining both design and process optimization to solve complex stamping challenges. Through continuous refinement and practical testing, we were able to achieve more consistent and reliable outcomes in automotive sheet metal production.

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