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In the forming of TB (Tailored Blank) side outer panel, splits frequently occur in the stretch flange areas. Most splits in these areas are categorized as two different types - one at the end of weldline in blank corner due to the local concentration of deformation on thinner or weaker material resulting from different material gauges or strengths and the other at the die corner due to the lack of draw-in of blank during stamping. Therefore, the proper design of blank shape, weldline placement and drawbead in the stretch flange area is crucial for the successful forming of TB side outer panel. In this paper, the design practice of TB stretch flange forming was investigated. The effects of the selected design parameters such a blank corner radius, weldline position and drawbead restraint forces were examined separately and the optimal TB stretch flange design was examined with respect to the several design parameters.

Automotive companies have tried to replace metals with plastic materials in order to reduce weight, cost and noise. This trend can be seen not only in interior and exterior parts but also in underhood parts of automobile. The representative example of replacing metals in underhood parts in power steering pump pulley. And we use phenolic engineering thermosets as substitute materials. This paper presents mechanical properties of phenolic engineering thermosets such as strength, flexural modulus, creep resistance, fluid resistance compared with nylon materials at high temperatures. Furthermore, in this study, we review a design-optimization process by Finite Element Analysis and tortional and static load test for insert. And then this paper shows how to validate phenolic power steering pump pulley as an application part of automotive.