Sheet metal stamping is one of the most commonly used manufacturing processes, and hence, much research has been carried for economic gain. Searching through the literatures, however, it is found that there are still a lots of problems unsolved. For example, it is well known that for a same press, same workpiece material, and same set of die, the product quality may vary owing to a number of factors, such as the inhomogeneous of the workpice material, the loading error, the lubrication, and etc. Presently, few seem able to predict the quality variation, not to mention what contribute to the quality variation. As a result, trial-and-error is still needed in the shop floor, causing additional cost and time delay. This paper introduces a new approach to predict the product quality variation and identify the sensitive design / process parameters. The new approach is based on a combination of inverse Finite Element Modeling (FEM) and Monte Carlo Simulation (more specifically, the Latin Hypercube Sampling (LHS) approach). With an acceptable accuracy, the inverse FEM (also called one-step FEM) requires much less computation load than that of the usual incremental FEM and hence, can be used to predict the quality variations under various conditions. LHS is a statistical method, through which the sensitivity analysis can be carried out. The result of the sensitivity analysis has clear physical meaning and can be used to optimize the die design and / or the process design. Two simulation examples are presented including drawing a rectangular box and drawing a two-step rectangular box.
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