Development and Optimization of an Aluminum Forming Process Using Finite Element Analysis as a Tool to Perform Parametric Studies

Forming of metal is a very challenging problem. To optimize a particular forming process the manufacturing engineer needs to determine the relationship between several dependent material properties and the independent forces on the metal that are generated by the press and tooling. The classical method to optimize a forming process relies on experience and trial and error development techniques. The forming of aluminum, when compared to steel, requires more development work to optimize the forming process. Finite element analysis provides a method to quickly perform the trial and error iterations necessary to optimize the forming of aluminum.