How Inverse Solver Technologies can Support Die Face Development and Process Planning in the Automotive Industry

With the availability of die face design tools and incremental solver technologies to provide detailed forming feasibility results in a timely fashion, the use of inverse solver technologies and resulting process improvements during the product development process of stamped parts often is underestimated. This paper presents some applications of inverse technologies that are currently used in the automotive industry to streamline the product development process and greatly increase the quality of a developed process and the resulting product. The first focus is on the so-called target strain technology. Application examples will show how inverse forming analysis can be applied to support the process engineer during the development of a die face geometry for Class 'A' panels. The drawing process is greatly affected by the die face design and the process designer has to ensure that the resulting drawn panel will meet specific requirements regarding surface quality and a minimum strain distribution to ensure dent resistance. The target strain technology provides almost immediate feedback to the process engineer during the die face design process if a specific change of the die face design will help to achieve these specific requirements or will be counterproductive. The paper will further show how an optimization of the material flow can be achieved through the use of a newly developed technology called Sculptured Die Face (SDF). The die face generation in SDF is more suited to be used in optimization loops than any other conventional die face design technology based on cross section design. A second focus in this paper is on the use of inverse solver technologies for secondary forming operations. The paper will show how the application of inverse technology can be used to accurately and quickly develop trim lines on simple as well as on complex support geometries.