#forming simulation

Incremental sheet metal forming simulation not only predicts common defects such as wrinkles, splits or springback but is also regularly used to accurately calculate blank shape and trim developments. In many cases, a sheet metal forming process starts with a 100% developed blank OR requires mid process trimming before final forming. In either case, manually developing the blank or trimming profile is a source of costly try out time, typically taking more than a few days.

Using the AutoForm Trim module, StampingSimulation.com reduces tryout time and cost by optimizing the required cutting profiles via AutoForm Incremental simulations. This means that every step of the sheet metal forming process is considered, unlike inverse one-step solutions and therefore, the resulting accuracy is much higher.

AutoForm Trim is an iterative process, similar to the shop floor method but entirely in the simulation environment and without the cost of manual labor and press time. Blank or trim developments are usually solved accurately within a few hours, a saving of many days on the shop floor. [Below: Simulation develops the blank virtually and accurately, through all forming steps.]  

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Sheet metal forming simulation can help tool and die designers to build tools right the first time, saving large amounts of time and money. In this case, Malbern Engineering in South Africa had designed and fabricated a tool for a new automotive project. During initial tryout, the process formed the part successfully. However, once the tool was set for production, constant splits resulted. Initially, a forming simulation of the current process was performed, to determine if the splits were expected. The forming simulation result shows that indeed, the material is predicted to split. This is due to excessive thinning in the current process. "I decided to modify the 1st stage form tool as per your recommendation and as you can see from the photo’s the proposal was successful.Thank you very much for your input. " Marco Smargiasso - Technical & Marketing Manager - Malben Engineering

A modification to the pre-form process was proposed, using sheet metal forming simulation to engineer and develop the shape. Based on forming simulation and engineering development, an optimized pre-form shape was developed. The pre-form shape stretched the material evenly to ensure no excess thinning occurred.

Because of the engineered pre-form shape, the final shape formed successfully, without splits and without excessive thinning. The result is successful and robust. Using sheet metal forming simulation, it was verified that the final shape can be formed without further stretching and without consequential failure. The final form simply moves material, rather than adding more stretch. The simulation shows success and reality agrees.

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