The numerical method of analysis plays a key role in simulation of sheet metal forming processes for design innovation through virtual manufacturing. Recently, important advances in research and development of the sheet metal forming processes have been made by many scientists and engineers. This paper covers general issues in sheet metal forming but deals with the most challenging subjects including finite element (FE) techniques, springback, hydroforming and process design. Furthermore, the results of the proposed benchmark problems in NUMISHEET 2002 with both experiments and simulation results will be discussed.