Applications of simulation techniques to sheet metal forming processes

Sheet metal forming is one of the most widely used processes in manufacturing. Traditional die design practice based on trial and error method is time consuming and expensive. For this reason, the simulation technique based on Finite Element Method (FEM) becomes more popular to develop and optimize die design. Two FE codes for the analysis of the sheet metal forming processes are presented in this paper. The one is a two dimensional implicit code named KSHELL, and the other is a three dimensional explicit code, ES-FORM. Draw bending, tube inversion and spring back processes were simulated by KSHELL. Three point bending, automotive panel stamping and square cup drawing with Tailor Welded Blanks (TWB) were simulated by ESFORM. The simulation results are discussed by comparing with experimental measurements.

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