Abstract
Structural analysis, in Abaqus, of a stamping die and subsequent morphing of the tool surfaces in AutoForm were performed to improve a sheet metal forming simulation. First, the tool surfaces of the XC90 rear door inner were scanned. They were not matching when the die was unloaded and could therefore not give any satisfying results in sheet metal forming simulations. Scanned surface geometries were then added to a structural FE-model of the complete stamping die and some influential parts of the production press. The structural FE- model was analysed with Abaqus to obtain the structural deformations of the die. The calculated surface shapes were then transferred to AutoForm where a forming simulation was performed. Results from the different sheet metal forming simulations were compared to measured draw in curves and showed a substantial increase in accuracy and ability to analyse dies in running production when the morphed surfaces were used.
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