Finite element analysis to optimize forming conditions for lower control arm

Finite element simulations for the press forming of a lower arm are performed using the explicit dynamic finite clement method (FEM) code RAM-STAMP. To optimize the press-forming conditions and secure a safe product without any failure, such as fractures and wrinkling, the FEM simulations are coupled with Taguchi's orthogonal array experiment. Three design variables-the friction coefficient, plastic anisotropy parameter, and blank shape-are selected to be optimized. The numeric simulations reveal that the blank shape is the most important variable, and its modification is most effective in optimizing the press-forming conditions for a lower arm. In addition, the modified blank shape produces a high yield ratio for the in-come coil. The simulation results are confirmed with experimental ones. [PUBLICATION ABSTRACT]