Investigation of sheet metal forming by numerical simulation and experiment

Two large sheet-forming simulation CAE systems — Autoform and Ls-dyna3D — being representatives of implicit and explicit solutions, respectively, are employed in the comparison of simulation results for a side-frame constituting the outer panel of a Santana 2000; validating experiments are also presented in this paper. Through the simulation calculation, the engineering strain and the thickness change of the blank during forming are compared and the comparison between the strain state and the FLD is given. The possible areas of wrinkling and failure in the course of pressing are determined. According to the comparison, the difference produced by two systems in dealing with problems is discussed, the cause of existing difference is analyzed and methods of reducing the difference are presented. Finally, the advantages and disadvantages of the two systems are considered.