Simulation of sheet metal forming processes has been in use for more than 25 years. The method requires input data including the geometry and material specification for the blank, CAD models of the tool geometry and process conditions such as blankholder force. Within a couple of hours a great deal of knowledge about the feasibility of the proposed process and tool design can be obtained. The results reveal potential problems with splits, wrinkles or excess thinning (figure 1) as well as allowing optimisation of the process to determine the optimum blank size and number of operations - many toolmakers now rely on simulation to confirm the process before physical try out.
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