An integrated numerical technique in determining blank shape for netshape sheet metal forming

A new blank design method is proposed based on iterative FE sheet metal forming simulations. An algorithm is introduced to approximately develop both CAD design and FE-virtually formed sheet metal parts onto a 2D plane. The errors between the original CAD design and the FE simulated parts can be characterised in both 2D and 3D spaces. An integrated numerical procedure for the netshape sheet metal forming process is detailed in the paper and a U-type channel part is taken as an example in the investigation.