Numerical simulations in optimisation of product and forming process

Modern systems for the development and manufacturing of new products are strongly connected to market demand. To achieve fast and effective response to market needs, the concept and design phase must take place in a virtual CA-x environment. Once the approximate product geometry is known, a numerical simulation has to be performed to study the forming process and appropriate tool design. After some iterations, product geometry, with some variants, is known and the best of them is chosen for further development. The number of stamping steps and the exact tooling geometry are determined. The stamping processes which are widely used in the manufacturing of sheet metal parts are hard to control, since they depend on numerous parameters relating to geometry and material type. The purpose of this paper is to present the industrial application of 3D numerical simulations using the PAM-STAMP program in the product and process development cycle. The simulations were performed during product and process development including tool design and manufacturing. The issues theoretically discussed in the first part of the paper will be explained by example. The time, costs and benefits analysis of using the numerical simulation in the product and process development cycle will also be discussed.