Abstract: In this paper, the die face structure of the outer panel of an AA6014-T4 aluminum alloy car bonnet is designed and optimized with Dynaform based on orthogonal experiment. The study shows that the most influencing factor for panel thinning rate is the draft angle of die face while that for thickening rate is its boundary extension. The optimum technological parameters obtained by optimization with other technological parameters fixed are: a boundary extension of 4mm, a punch radius of 20mm, a draft angle of 20 degrees and a die radius of 10mm. They are verified by simulation and test, and the resulting panel has good forming quality without cracking and wrinkling.

Key words: aluminum alloy, bonnet, stamping forming, die face, orthogonal experiment