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Based on mechanics principles and solved numerically on a super workstation, Ford has developed various sheet metal forming analysis computer programs. This paper describes the features in these programs. Several actual design examples illustrate how stamping engineers use these tools to evaluate and improve their design.

In this paper, we introduce a numerically stable 2D computer model for sheet metal forming analysis based on the membrane theory. It simulates both axisymmetrical and plane strain cases with various restraining and friction conditions. We implemented a more realistic material model that accounts for cyclic loading and unloading. Also, the difficult frictional force reversal problem has been overcome. A simulation package released within Ford Motor Company has proven robust and accurate for applications to industrial cases.

An existing binder computer program including a pre-processor to establish a finite element model has been modified so that it can analyze the blank of a trunk deck-lid outer panel with pre-bend. The formula for computing the spring-back shape after a blank under cylindrical bending with a specific radius is derived in this paper. Using this spring-back shape as a starting configuration instead of a flat blank, the modified program computes the binder wrap of an automotive body panel. Two trunk deck-lid outer panels were analyzed to illustrate the effects of pre-bend.