Application of computer modelling in part,die, and process design for manufacturing of automotive stampings

Recent studies in sheet metal forming, conducted at universities world wide, emphasize the development of computer aided techniques for process simulation. To be practical and acceptable in a production environment, these codes must be easy to use and allow relatively quick solutions. Often, it is not necessary to make exact predictions but rather to establish the influence of process variables upon part quality, tool loads, material flow, and material thickness variation. In cooperation with its industrial partners, the ERC for Net Shape Manufacturing at the Ohio State University has applied a number of computer codes for analysis and design of sheet metal forming operations. This paper gives a few selected examples taken from automotive applications and illustrates practical uses of computer simulations to improve produtivity and reduce tool development and manufacturing costs.