FE simulation for concurrent design and manufacture of automotive sheet-metal parts

FE simulation can be an efficient means of enabling concurrent design and manufacture, particularly for those components that are formed by plastic deformation. By applying FE simulation to the three stages of the product development—part design, process model development and manufacturing try-out the design and manufacture of automotive sheet-metal parts was effected concurrently. Considering that numerical errors are still inevitable and some technical problems encountered in FE simulation could not still be overcome using currently available FE codes, FE simulation was treated as a means to gain initial forming experience through numerical trials. The results were verified using practical manufacturing knowledge which enabled the definition of computational errors. Further simulation was conducted to develop material and process design considerations by addressing part-quality issues. Three parts were studied—the deep drawing of an oil pan, and the stamping of inner and outer panels of an automobile.