Advances in One Step Solvers for Formability Analysisat Styling, Product and Process Design Stages of Automotive Panels

The paper provides an overview of recent advances and applications of One Step FEM solvers in the automotive industry. The advances include, among other things,

1. 1.
   Enhanced pre-processing (e.g. i. Integration with CAD Systems, ii. Automeshing),
2. 2.
   Die processing geared functions (e.g. i. Automatic tipping, ii. Autoboundary conditions; to reduce effort in selecting the boundary conditions for achievement of a specific target strain in the panel),
3. 3.
   More robust mechanics and realistic modeling of process (e.g. i. Autobending to accommodate membrane as well as bending and unbending effects, ii. Passive force formulation for a more realistic modeling of the external forces required to form the part, as well as iii. Curved binder capability; for more accurate prediction of binder effects), and
4. 4.
   Enhanced post-processing and interpretation of results (e.g. i. Residual stresses, ii. Advanced FLD manipulation, iii. Edge movement on curved binder)

The paper will focus on the mechanics issues and starts by discussing the role of One Step versus Incremental Solvers for panel design and development. The paper will then illustrate the application of some advanced capabilities of the One Step solvers, and FAST_FORM3D in particular, at Styling, Product and Process Design stages, and elaborate on their implications on the simulation accuracy. Many of the elements discussed in this work form the basis of an interactive draw die development system, currently under development.