Sheet Metal Forming: Advanced Finite Element Method for Industry Leading Simulation

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

Using advanced FEA tools for sheet metal forming design and simulation, the feasibility of the project at hand is evaluated including predictions of the geometrical accuracy, cracking behavior, risk of cracking, and formability. The simulation results show the product’s characteristics such as wall thickness distribution, edge curvature, and the hardness distribution in forming steps.

Metal Forming Finite Element Method simulation Abaqus Ansys Msc Simufact Nastran ls-dyna FEA 3

Sheet metal components are highly suited to lightweight constructions. Different methods of sheet metal forming can be used depending on the geometry of the desired part. Based on the characteristics of each deformation process, the forming engineer can choose between: Deep drawing, ironing, punching, bending, stamping, and a variety of other manufacturing processes. Due to the geometric complexity of the parts being manufactured, additional multistage forming that combines different processes is frequently required within a phase of production. Therefore, production is usually achieved by automated transfer or stage pressing, or by progressive tools.

Transfer and Progressive Die Stamping

In transfer die stamping, a strip of metal is fed into the first station of a mechanical transport system, where the blank for the component is cut from the strip. The blank is then transferred mechanically through various forming stations until a finished part is produced. These different forming stations are necessary for the various forming operations such as deep drawing, trimming, piercing and flanging.

Using special purpose FEA software such as Deform, Simufact Forming, Ls-dyna, Abaqus and Autoform enables us to rapidly and accurately simulate the entire stamping process including drawing and secondary operations as well as springback. The simulation and results evaluation provided with all the necessary information to design the stamping process. 

Stamping Nakajima Test Forming Metal Abaqus Ansys Msc Simufact Nastran Code aster ls-dyna FEA

Tube Hydroforming

Tube hydroforming is used in the production of various tubular parts, which are highly resistant and light. Hydroforming is particularly interesting for the automotive industry as it offers important advantages from various perspectives. It allows for greater freedom in designing parts and at the same time makes the parts highly resistant and light. Hydroforming also allows for savings in material usage.

Our FEA Solution based on special purpose software and their customization with programming, enables us to carry out a complete virtual tryout of the hydroforming process involving all process steps, such as bending, preforming, hydroforming, annealing, calibration and cutting. In addition, we can generate and evaluate alternative tool designs and process layouts as well as find the best forming process for hydroformed parts.

Metal Forming Finite Element Method simulation Abaqus Ansys Msc Simufact Nastran ls-dyna FEA

Hemming

Accurate hemming is very important since it affects surface appearance and surface quality, two important aspects which attract the attention of potential customers. Material deformations, which occur during the hemming process, can lead to dimensional deviations and other typical hemming defects, including splits and wrinkles in the flange, material overlaps in the corner areas and material roll-in.

Simulation driven design with FEA software and their customization ability enables us to efficiently plan the hemming process and supports you in roll and table top hemming. Our simulation include prediction of full assembly springback after hemming also.

Sheet Metal Hot Forming

For the automotive industry hot Sheet Metal Hot Forming has become increasingly important in meeting specific requirements for lower overall weight and higher crash safety. Parts produced by hot forming are characterized by high strength, complex shapes and reduced springback effects.

Metal Forming simulation damage limit diagram finite element Abaqus Ansys Msc Simufact Nastran ls-dyna FEA