Material optimization: A case study using sheet metal-forming analysis

This paper focuses on material optimization by reduction in raw material size for sheet metal components. Panel roof, an automobile component is chosen for analysis. Using a commercial explicit solver, the sheet metal-forming process is analysed. To represent the actual tool profile in the analysis, computer-aided design (CAD) model of the tool geometry is developed by scanning the die in coordinate measuring machine (CMM). Forming limit diagram (FLD) and percentage reduction in thickness are checked in the finite element analysis (FEA). Experimental verification of the optimized blank is done by circular grid analysis technique. Difference in major strain varies from 2 to 10% and difference in minor strain varies from 0 to 6%. Weight savings of about 1.57% is achieved in the current work.