Adaptive mesh optimization for improved one-step forming

To reduce the simulation time and improve solution accuracy, an adaptive mesh optimization method is proposed for one-step forming simulation of auto-body panels. For a given auto-body part model, the state variables of model, such as thickness, strain and stress, is firstly estimated through one-step inverse forming method. Incorporating the distribution of these physical properties and geometric characteristics of model, an adaptive node placement technique is presented, which implies that in the regions with high curvature or strain-rate a high mesh density is desirable and on the contrary it is sparse. Simultaneously, the features of the original mesh, such as welding point, a stiffener for reinforcement, forming lines or holes in the interior of model, are preserved in the process of mesh optimization. Finally, numerical examples are shown to demonstrate that the proposed optimization method here exhibits good performance.