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The Sheet Metal Forming Simulation Research Group Japan, organized by the authors in September 1990 with the cooperation of Japanese car manufacturers, steel and aluminum producers and computer hardware and software companies, concluded its activities in September 1996. In this paper, the authors summarize the accomplishments of the group during the last 6 years. The paper consists of five parts. In the introduction, the historical background of FEM development is presented. Then, the situation of the Japanese automotive industry in the 1980's is described with emphasis on circumstances leading to the use of FEM in the design of stamping processes. Next, the motives behind the establishment of the Sheet Metal Forming Simulation Research Group in Japan are explained. Subsequently, the objectives and aims of the group activities are discussed. Then, examples of simulations done by members of the group. are presented.

Finite element modeling (FEM) can be a valuable addition to computer—integrated manufacturing(CIM) along with other kinds of analysis and representational tools such as computer—aided design(CAD), manufacturing(CAM) and engineering(CAE). A FEM program for analyzing sheet stamping operations has been developed using an explicit elastic—plastic formulation based on nonlinear membrane theory and Coulombic friction. Simulations of typical automotive stamping operations (Honda City front fender, Toyota oil pan, and Mazda RX—7 front and rear fenders) have been carried out and results presented. Single—action press operation is simulated in three stages and a linear shell program is used during the initial stage. The ability to obtain results for complex parts encourages the future use of FEM in conjunction with CAE, CAD, CAM in an interrelated CIM system.