Optimization of sheet metal forming processes by the use of numerical simulations

If the final part is to be produced without any defects, the development process has to be supported by means of numerical simulations based on finite element method (FEM). The experiences gained with optimization of sheet metal forming processes are presented on the industrial examples. The presented examples are carefully selected in order to present all important issues concerning sheet metal forming: determination of optimal product shape and optimal initial blank geometry, prediction of fracture, prediction of final sheet thickness, prediction of wrinkling, prediction of loads acting on the active tool surfaces, prediction of springback and residual stresses in the product. The results of the numerical simulations were compared to the samples from the production processes. Reliability of the results, costs, benefits, and times required for performing numerical simulations are evaluated. (C) 2002 Published by Elsevier Science B.V.