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Permanent deformations of AA6016 sheet metal parts after paint drying processes in car manufacturing

Permanente Deformation von AA6016 Tiefziehteilen nach dem Lacktrocknungsprozess in der Fahrzeugproduktion
 
: Regensburger, Jochen; Albiez, Christoph; Ackert, Patrick; Nicolai, Jan-Philipp; Drossel, Welf-Guntram

Liewald, Mathias:
International Conferences on New Developments in Sheet Metal Forming/Hydroforming of Sheets, Tubes and Profiles 2016 : 10.-11. Mai 2016, Fellbach; NEHY 2016
Fellbach, 2016
ISBN: 978-3-88355-411-2
pp.127-142
International Conferences on New Developments in Sheet Metal Forming/Hydroforming of Sheets, Tubes and Profiles <2016, Fellbach>
English
Conference Paper
Fraunhofer IWU ()
paint drying oven; multi-material car bodies; FEM; viscoelastic behaviour; aluminium

Abstract
In order to produce lightweight cars, aluminium alloys are widely used in modern car bodies. From the point of view of designers, especially outer shell panels can be optimized to reduce weight, because their contribution to functional values like crash performance or car body stiffness is quite low. On the other hand there are some challenges for car body production. After the press and body shop, the bodies-in-white pass through several paint drying ovens, where also alloys of the 6xxx series become heat-treated. Consequently, different thermal expansion coefficients as well as thermal gradients lead to high stresses within multi-material car bodies at maximum temperatures of almost õ=200 °C. In this work, the nonlinear deformation behaviour of an aluminium part is tested in an oven and recalculated by FE-simulation, where also ist viscoelastic behaviour is taken into account. The test results show a good accuracy of the FE-simulation considering the relevant influence factors like pre-strain dependent material behaviour, Temperature distribution and initial deviations that occur during the manufacturing processes. Based on these results novel deformation analyses of car bodies in automotive paint drying processes can be performed. Also important knowledge for the need of preliminary forming simulations is gained.

: http://publica.fraunhofer.de/documents/N-393588.html