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The work describes an approach for a closer interface between product design and manufacturing. Starting from the part print a finite element model of the final part is constructed. The model is used for a one step unfolding of the part to determine the blank shape. In addition, by tracking the shape of the material “finite” elements before and under unfolding, the approximate forming severity of the stamping can be obtained. The one step unfolding solution also provides the thickness distribution together with the yield stress distribution in the stamped part. This information is of great value to product design for the performance of a more realistic fatigue analysis. Since during product design many design alternatives are to be evaluated, the finite element formulation used at this stage is based on a one step approach, with the emphasis on solution speed as opposed to exactness.

The paper describes a system currently under development, intended to be the spine for organizing an open-ended knowledge-based system for stampings within the sheet metal industry. The system is designed for those not necessarily expert in plasticity and strain theory, as well as applications where lead time is of prime importance. The objectives of the system are to develop: i a common vocabulary for BASIC SHAPES and DEFORMATION MODES ii an open-ended filing system for the organization of the knowledge i.e. the documentation of solutions and procedures used, as well as assessing historical data iii a procedure for deriving the FIRST FORM SHAPE and the number of forming stages and iv a system for the assessment of forming severity, force and energy calculations, material selection, tribological requirements and process planning.