Applications of finite element simulation in the development of advanced sheet metal forming processes

Sheet metal forming is widely used in automotive, aviation, packaging, and household goods. It is most popular for the manifold technical feasibilities in manufacturing, high precision, mass production, and short processing time. Modern automotive concepts demand a weight reduction by using high strength materials and excellent crash performance, which requires innovative simulation techniques in the design and development phase as well as suitable processing chains. The conventional manufacturing planning method takes a lot of time, hence the Finite Element method (FEM) is applied to reduce the lead time. The FEM prediction accuracy depends on the proper selection of a material model, quality of input parameters, actual operating conditions, and many other factors. This study involves new developments in the sheet metal forming technology, the most influencing factors of the forming process and case studies to justify it. The first case study explains the springback analysis and springback compensation of AlMgSi (6xxx series)-panels. The second case study describes the thickness analysis and deformation behaviour of patchwork blanks for hot stamping processes.