How the Modeling of Virtual Materials Can Secure Part Feasibility

The paper describes a method applied to show how to perform a steel sheet metal sensitivity analyses while the material is subjected to stretch forming and deep drawing. It is shown that the sensitivity analysis provides meaningful results. Simulations were run with simplified laboratory geometries and extended for the most complex automotive parts. The variety of likely numerical runs are dramatically reduced by means of a statistical design of experiments, minimizing the number of simulations required for daily use. As a result it is possible to choose the optimal material for a specific forming process and part, as well as to assess the expected scattering in the material properties.