Stamping Process Design and Forming Analysis of Heat Shield on Exhaust Manifold

This article focuses on the stamping process of the heat shield on the exhaust manifold, a complex curved thin-walled part, and conducts a systematic process design and forming analysis. Three dimensional modeling was carried out using UG software, and key process designs such as stamping direction setting, die surface design, and mesh division were completed based on the Autoform R8 platform. Through finite element simulation, the forming limit, thinning rate, and normal rebound of the parts were predicted and evaluated. The analysis results indicate that there is no risk of fracture for the parts under this process scheme. The maximum thinning rate is 30% and it is located at the local reinforcement rib. The rebound amount in the key assembly area is less than 0.5 mm, which meets the tolerance requirements. This study validated the feasibility of the process plan and developed a technical path of “simulation driven optimization”, providing an effective theoretical basis and practical paradigm for the development of similar complex structured stamping parts.