A computational response surface study of three-dimensional aluminum hemming using solid-to-shell mapping

Guosong Lin, Jing Li, S. Jack Hu, Wayne Cai

Research output: Contribution to journalArticlepeer-review

20 Scopus citations


Hemming is a manufacturing process of folding a panel onto itself or another sheet. Quality of hemming is characterized by geometry and formability. This paper presents a response surface study of three-dimensional (3D) curved-surface-curved-edge hemming of an aluminum alloy, AA6111-T4, using finite-element (FE) analysis. Solid elements and explicit FE solver are used for simulations of flanging, pre- and final hemming, and shell elements with implicit solver are deployed for springback prediction. A novel procedure called "solid-to-shell mapping" is developed to bridge the solid elements with the shell elements. Verified to be accurate and efficient, the model is utilized in a central composite design to quantitatively explore the relationships between certain key process variables and the hem dimensional quality and formability. The most significant variables are identified as: (i) prehemming angle on roll-in/roll-out; (ii) nominal surface curvature on sheet springback; and (iii) initial sheet strain and flanging die radius on the maximum hemline surface strain of the produced hem. These results provide insights for process parameter selections in designing and optimizing 3D hems under material formability constraints.

Original languageEnglish (US)
Pages (from-to)360-368
Number of pages9
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number2
StatePublished - Apr 2007
Externally publishedYes


  • Aluminum hemming
  • Central composite design
  • Dimensional quality
  • Formability
  • Solid-to-shell mapping

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering


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