A simplified finite element simulation system for prediction of a springback correct die shape has been developed for the sheet metal stretch forming process. This system has been designed for use in conjunction with a "discrete-die" reconfigurable tool. The simulation system takes into account the deformation of the compliant layer that is required for use with a discrete die. The system is highly automated, and is designed to be used by a tool design engineer with little finite element modeling experience. The system performs initial forming checks to determine if the part can be formed with a particular reconfigurable tool, it then prepares and submits a finite element model of the process, and retrieves and analyzes the output of the calculation. A die design algorithm is incorporated for prediction of the springback corrected die shape. The predicted die shape and the desired forming trajectory are then downloaded directly to a web-server database, to be accessed by the reconfigurable tooling system.
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