Finite Element Modeling and Optimization of Quick Super-plastic Forming for the Side Wall Outer Panel of London Metro Vehicle

摘要

Quick super-plastic forming has been developed as a high-volume, hot blow forming process for vehicle components, enabling higher volume applications than traditional super-plastic forming. It was chosen as the manufacture process for the side wall outer panel of London metro vehicle, which has complex shape and the requirement of high-volume. In this paper, the finite element simulation of super-plastic forming process for the side wall outer panel of London metro vehicle was conducted. The pressure-time relationships for a given optimum strain-rate and the thickness distribution are calculated. Based on the finite element modeling, the influences of key factors such as the frictional coefficient on the thickness distribution and pressure during the forming process were studied. The quick superplastic forming has been successfully implemented for the side wall outer panel of London metro vehicle. Finally, experiments were performed and it is found that numerical results are in good agreement with experimental values.