We would like to explore the capabilities of forming simulation, as well as provide some descriptions of how the technology works. So here is a quick summary of a few typical applications of press forming simulation technology. It helps to understand if you are aware that press forming simulation is actually a specific application of the Finite Element Method (FEM also known as FEA).

Material yield (utilisation) calculations and blank shape estimates

Using a 3D CAD model of the final part, the data is meshed automatically and then “unrolled” or developed to a flat blank shape. From here blank nesting and rectangular, trapezoid or any other shape fitting can be applied. The final data produced is a 2D CAD line which can then be used to calculate material utilisation across any blank nesting or shape configurations.

Tip angles (or part tipping) and undercut checks

Using the 3D CAD of the final part shape, the data is automatically tipped into the most suitable pressing angle with the intent to ensure no elements in the mesh “undercut” the vertical motion of a press machine. This step provides a very quick indication of the possibility of forming the desired part shape in one process or if there is a need to do it in two or three or more processes. If there are undercutting areas, they are highlighted and decision can be made as to whether the part shape can be changed (to avoid the undercutting) or if an additional forming process is needed. This step sets the press tip angles and positions the 3D CAD model into the pressing coordinate system, ready for further die face designing.

Forming simulation (or drawing simulation)

Of course this is the main purpose of this website, but the result is so much than just a simulation. At first, die face data has to be created. Using the final part shape that has been tipped in to the pressing direction, die face surfaces are created. For example in a simple crash form, the boundaries of the part simply need to be extended, but in a draw process addendum and binder surfaces need to be created. With this, the earlier developed blank shape (square, pre-trimmed or otherwise) is used with the newly created die face surfaces to run the simulation.