Applications of a Two-Dimensional Metal Forming Analysis Tool to Production Stamping Problems

In any new car program many factors influence lead time and associated cost. One of these factors is die tryout. To reduce time and expense the BOC Flint Automotive Division is complementing this function with simulation methods. Changes in geometry, bead height, material properties, etc., can be evaluated more quickly at a lower cost using this analytical approach.

In most cases failure occurs in highly localized areas of the die. Quite often a plane strain or axisymmetric assumption can be made along a critical die contour. In these cases a two-dimensional analysis can be used to determine the strains induced by the forming operation. The objective of this paper is to demonstrate the successful application of these two-dimensional metalforming techniques within the Flint Automotive Division. These applications also illustrate the ability of this technology to bridge gaps between Die engineering and design concerns while abetting simultaneous engineering.