PAM-STAMP in the simulation of stamping process of an automotive component

The present study focuses on the stamping process simulation of automotive component using PAM-STAMPTM simulation software. A die geometry of an automotive component has been simulated in this study. Safe limit of blank holder forces have been identified with respect to different parametric conditions. Plain carbon steel, reinforced steel and aluminum alloys have been used as the work materials for simulation.Safe limit of blank holder forces with respect to strain hardening exponent (n), friction coefficient between the blank sheet and the die (μ) and punch speed (v) have been evaluated and analyzed.The result shows that the upper and lower limits of blank holder forces for plain carbon steel are 240 kN and 125 kN while for aluminum alloy AC120; the limit is between 85 kN and 50 kN. This indicates that plain carbon steel can be deformed without having any tear for a higher value of the blank holder force while aluminum alloy can be deformed without having any wrinkles at much lower value of the blank holder force. The upper bound limit BHF values for reinforced steel and aluminum–magnesium alloy are 220 kN and 200 kN respectively.It has also been observed that if the strain hardening exponent (n) of the work material increases, the blank holder force also increases. However, with the increase of friction coefficient (μ) or the punch speed (v), the blank holder force decreases.