Sheet Metal Forming Simulation and Real World Tooling

In a modern day draw simulation; our objective has always been to verify the formability of the deformed blank. We then utilize the output of the simulation to ascertain the forces required to form the part. Little time is spent attempting to verify if our design for the die is capable of reproducing these results. Most simulation assumes the tools are rigid. The real expertise comes when you can reproduce that scenario in an actual tool that makes parts in a consistent manner. This study follows a real world die development and build project, where the initial tryout was completely different from the simulation results, binder deformation has played a key role which differs the simulation results in which all tools are assumed to be rigid. Further simulation with a flexible binder has been performed, also compared to the real world solutions that were developed to make a good part. This study also provides valuable information for exploring the next generation of forming simulation needs. A major advance in simulation technology would be to answer the question of how simulation can compensate for these inadequacies. Through this study, it is clear that optimization analysis for various tooling needs to be shortened the tooling process time and reduction of the cost is an obvious trend in the near future.