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The paper provides an overview of recent advances and applications of One Step FEM solvers in the automotive industry. The advances include, among other things, 1. Enhanced pre-processing (e.g. i. Integration with CAD Systems, ii. Automeshing), 2. Die processing geared functions (e.g. i. Automatic tipping, ii. Autoboundary conditions; to reduce effort in selecting the boundary conditions for achievement of a specific target strain in the panel), 3. More robust mechanics and realistic modeling of process (e.g. i. Autobending to accommodate membrane as well as bending and unbending effects, ii. Passive force formulation for a more realistic modeling of the external forces required to form the part, as well as iii. Curved binder capability; for more accurate prediction of binder effects), and 4. Enhanced post-processing and interpretation of results (e.g. i. Residual stresses, ii. Advanced FLD manipulation, iii.

The effect of binder shape on the formability of metal stampings is addressed in this work. The paper starts with a discussion of a binder development approach for developable or near developable binders. An FEM based test for closeness to developable surfaces is also presented. In this case, the binder surface is meshed using standard FEM discretization techniques. The test is used as an evaluator for the proneness of wrinkle formation at the binder closing stage under the binder surface. The formability of a door outer panel is evaluated and the forming severity related to binder shape. It is shown that addendum and binder designs are key process variables that have to be designed up front and related to product characteristics.