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Sheet metal forming simulation and Springback prediction based on finite element analysis

Spathopoulos Stefanos-Christos

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Summary

Sheet metal forming is one of the most important manufacturing processes applying in many industrial sectors with one of the most prevalent, the automotive industry. The main purpose of that operation is to achieve the production of a desired formed shape blank, without causing any material failures. That specimen should as well conform to the appropriate dimensions and tolerances, after reaching the unloading state. Over time, the automotive industry is constantly investing in material optimization, aiming at achieving a high -strength and reduced mass combination. As such, materials become increasingly complex, since their microstructure changes, which results in non-linear properties as well as complicated behaviors. Consequently, by aiming to improve the predictability, accuracy, and quality of a study, finite element software is frequently used in such processes. These simulation tools, conduct manufacturing operations analysis and after their results are elicited, they are cross-checked with some experimental tests and thereby extract precise conclusions concerning materials behavior. During this thesis, the sheet metal forming simulation of an experimental automotive specimen as well as its spring-back prediction will be implemented by the finite element method. Initially, the related geometry, as well as its corresponding forming tools, will be designed through CAD software and then they will be imported in a simulation software through which an FEA analysis will be applied.

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