Development of FEM for Sheet Metal Stamping

Finite element modeling (FEM) can be a valuable addition to computer—integrated manufacturing(CIM) along with other kinds of analysis and representational tools such as computer—aided design(CAD), manufacturing(CAM) and engineering(CAE). A FEM program for analyzing sheet stamping operations has been developed using an explicit elastic—plastic formulation based on nonlinear membrane theory and Coulombic friction. Simulations of typical automotive stamping operations (Honda City front fender, Toyota oil pan, and Mazda RX—7 front and rear fenders) have been carried out and results presented. Single—action press operation is simulated in three stages and a linear shell program is used during the initial stage. The ability to obtain results for complex parts encourages the future use of FEM in conjunction with CAE, CAD, CAM in an interrelated CIM system.