Advance in Sheet Metal Forming - One-step Solution, Multi-Beads, Gravity Prebending, Auto Nets, and Local Compensation

Some of the new features developed since the last conference will be discussed. 1)A fast one-step sheet metal forming program Developed mostly for blank size estimation and forming effect initialization in crash simulation, this powerful feature allows hundreds of parts to be simulated in a very short time. 2)An improvement to the contact draw bead Developed together with Ford Motor Research and Advanced Engineering Laboratory, multiple beads can now be generated automatically based on the base draw bead definition, to represent the actual bead width and forces. This more realistic approach allows for a better blank size prediction and utilization. 3)Pre-bending for gravity simulation Developed together with Ford Motor Company, blanks can now be pre-bent to simulate the various scenarios of stamping press destacker loading of the sheet blank to the draw die. This new approach produces a more realistic gravity-loaded blank shape, resulting in shorter die travel and better stamping quality. 4)Automatic fixture nets for free-standing springback simulation This feature allows for automatic generation of fixture nets of user-specified sizes, in user specified locations, with contacts automatically established, for a free-standing springback simulation. 5)Springback compensation for localized multi-regions Developed together with Chrysler LLC, local compensation of stamping dies can be extended to multiple regions.