Process Modeling for Precision Forming of Discrete Parts – State of the Technology and Critical Issues

This paper presents an overview on the application of FE simulation as a virtual manufacturing tool in designing manufacturing processes for precision parts. The processes discussed include forging, sheet metal forming and hydroforming. Determination of reliable input parameters to simulate a process is a key element in successful application of process simulation for process design in all the mentioned areas. These issues are discussed in detail. Practical examples of application of FE simulation are presented for improvement of the existing metal forming process and/or designing new metal forming process for manufacturing discrete precision parts in forging, sheet metal forming and hydroforming.