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Process simulation for product and process design is currently being practiced in industry. However, a number of input variables have a significant effect on the accuracy and reliability of computer predictions. A study was conducted to evaluate the capability of finite element method (FEM) simulations for predicting part characteristics and process conditions in forming complex-shaped, industrial parts. In industrial applications, there are two objectives for conducting FEM simulations of the stamping process: (1) to optimize the product design by analyzing formability at the product design stage and (2) to reduce the tryout time and cost in process design by predicting the deformation process in advance during the die design stage. For each of these objectives, two kinds of FEM simulations are applied.

Recent studies in sheet metal forming, conducted at universities world wide, emphasize the development of computer aided techniques for process simulation. To be practical and acceptable in a production environment, these codes must be easy to use and allow relatively quick solutions. Often, it is not necessary to make exact predictions but rather to establish the influence of process variables upon part quality, tool stresses, material flow, and material thickness variation. In cooperation with its industrial partners, the ERC for Net Shape Manufacturing of the Ohio State University has applied a number of computer codes for analysis and design of sheet metal forming operations. This paper gives a few selected examples taken from automotive applications and illustrates practical uses of computer simulations to improve productivity and reduce tool development and manufacturing costs.