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Based on mechanics principles and solved numerically on a super workstation, Ford has developed various sheet metal forming analysis computer programs. This paper describes the features in these programs. Several actual design examples illustrate how stamping engineers use these tools to evaluate and improve their design.

In this paper, we introduce a numerically stable 2D computer model for sheet metal forming analysis based on the membrane theory. It simulates both axisymmetrical and plane strain cases with various restraining and friction conditions. We implemented a more realistic material model that accounts for cyclic loading and unloading. Also, the difficult frictional force reversal problem has been overcome. A simulation package released within Ford Motor Company has proven robust and accurate for applications to industrial cases.

This paper describes the capability of the binder analysis in Ford's three dimensional sheet metal forming program. Three real design examples illustrate that the program could detect buckling/wrinkling in auto-body panels during binder set (wrap). With revision of the binder surface design, the program predicted buckling/wrinkling on those panels disappeared. The computing time for each evaluation of the binder set of a panel is in order of minutes on a super workstation; therefore, it has been used as a design analysis tool.