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This work presents comparisons of finite element model predictions of static and dynamic denting with experimental results. Panels were stamped from 0.81, 0.93 and 1.00mm AA6111-T4 and then paint-baked to produce representative automotive outer body panels. Each type of panel was statically and dynamically dented at three locations using a 25.4mm steel ball. Static denting was accomplished with incremental loading of 22.24N loads up to a maximum of 244.48N. Dynamic denting was accomplished by dropping the steel ball from heights ranging from 200mm to 1200mm. Multi-stage finite element analysis was performed using LS-DYNA1 and ABAQUS2 to predict the entire process of forming, spring-back, denting and final spring-back of the dented panels. The predicted results show good correlation with the experiments, but also highlight the sensitivity of the predictions to formulation of the finite element problem.

This work presents a numerical method for predicting the final shape of stamped automotive assemblies. Each assembly was manufactured by laser trimming and spot–welding two separate stampings together. The panels that represented the ‘inner’ of the automotive assembly were stamped from 1.04mm or 1.63mm AA5754 sheet, while panels representing the ‘outer’ were stamped from 0.93mm AA6111 sheet. The finite element method (FEM) was used to predict the final shape of the automotive assemblies. For these predictions, finite element models of the forming, individual panel springback, and final assembly springback operations were performed. The laser trimming and spot–welding processes were modelled using pre–processing software. Experimental validation of the finite element models was undertaken using a coordinate measuring machine (CMM) as well as a non–contact surface digitizing technique.