Parameter Study for Optimum Design of Sheet Metal Forming Processes with Inverse Finite Element Analysis

Abstract

A new inverse finite element method is introduced for direct prediction of blank shapes and strain distributions from desired final shapes in sheet metal forming. The inverse finite element method deals with the geometric compatibility of finite elements, plastic deformation theory, simplified boundary conditions, minimization of potential energy with constraints, and a proper initial guess. The inverse finite element method with the optimization scheme can estimate values of non-shape parameters (blank holding force, bead force) directly as well a s shape parameters (blank shapes). The algorithm developed is applied to some examples in order to confirm its versatility of application by demonstrating the reasonable numerical results. Rapid calculation with this algorithm enables easy determination of various process variables for design of sheet metal forming process.