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 element method (FEM) code PAM-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.