Virtual Forming and Gage Thickness Optimization of Sheet Metal Components

With the advent of high-speed computers more and more theoretical research in manufacturing area is transferred to technology that enable complex CAD modeling and solution of the onlinear, large deformation finite element problems. All OEMs require their suppliers to use the simulation tools before prototypes are made on the shop-floor. Virtual simulations help produce an array of acceptable designs some of which give information on identifying and setting the optimum values of the forming process parameters. This paper discusses the application of rotatable orthogonal array (OA) and 5-axes response surface methodology (RSM) to identify the optimum values related to metal forming of an example part with thickness as the response.