Stamping and Hydroforming Process Simulations with a 3D Finite Element Code

In the automotive industry, the finite element analysis (FEA) has been extensively used in metal forming process simulations during recent years. A number of papers have been published to document these progresses, especially for the 2D applications. Up to very recent years, due to the advent of high speed computers, the use of 3D finite element codes to model complex sheet metal forming and hydroforming processes has become possible. This paper is intended to present some of the applications using a commercial 3D finite element code, DYNA3D, to production-type stamping and hydroforming process simulations. The modeling methodology and some of the correlations between models and experimental measurements are given herein. Also, the benefits of using the FEA process simulation at the early stage of the product developments are discussed.