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STATE-OF-THE-ART IN THE USE OF (LS-DYNA) FORMING SIMULATION IN HYDROFORMING AND PRECEDING PROCESSES

Rapid and reliable methods for component development and economic manufacturing layout are today crucial factors for the application of hydroforming techniques in mass production of lightweight components for the automotive industry. Optimum design of components taking into consideration special process-specific factors enhances safety and also the cost-effectiveness. The feasibility study, the component configuration and definition of a production sequence are closely interlinked. Once the approximate product geometry or component design, respectively, is known, a FEA (Finite Element Analysis) simulation has to be performed to study the forming process and appropriate die design. The FEA has become an established feature of hydroforming technology. The objective of FEA study is to replace costly and elaborate experimental testing by fast, low-cost computer simulation.

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