Development Of Sheet Metal Multi-Process Forming Simulation Pre-Process System

Due to the developments in the methods of finite element simulation, as well as in computational facilities, sheet metal forming numerical simulation has become an everyday tool in engineering practice. Therefore resent sheet metal forming numerical simulation technology is applied in the single process simulation which is used to predict the defects of the process. However, this application cannot forecast the problems appeared in the complete processes. Multi-Process simulation is able to analyze the complete processes, according to the simulation of each process, which truly simulates the whole forming processes of the product.This research is supported by NSF named:"The Independent Research of High-speed Simulation and Optimal Process Design aiming at the Formability of Automobile Panel"(NO.50575080) and National 863 Program:"The Formability and Optimal Process Design Based on the Simulation of Automobile Parts"(NO. 2006AA04Z140). Based on the research of Multi-Process simulation theory and the use of Computer Graphics and finite element theory and the application of object-oriented method, a Multi-Process System is developed on the sheet metal forming simulation software FASTAMP which will solve the complete processes simulation on drawing, flanging, trimming and springback simulation.In this paper, the author discussed the Multi-Process pre-process system's sheet metal mesh, constrain, material and tailor welded blanks model and analyzed the processes of drawing, flanging, trimming and spingback simulation and studied the drawing, flanging process parameter definition, tool definition and assemble as well as drawbead and cutline simulation, trim line of trimming process and constrain points of springback process and so on key technologies.On this basis, the paper introduced the development environment, coding language and development tool and launched the Multi-Process System Design and Development. With the application of object-oriented program design, the author developed the process-oriented Multi-Process simulation pre-process system with drawing, flanging, trimming and springback simulation.Finally, compared with the real stamping result, the simulation of vehicle floor and fender indicate that the Multi-Process System has well reliability and accuracy and fulfills the requirement of reality.