FE Modeling of Cushion 3D Motion for Sheet Metal Forming Simulation

Abstract: Nowadays FE-simulations for sheet metal forming process are used to reduce the tryout phase in automotive industries. But the complex forming simulation processes are very challenging. One of the challenges is to create an FE-model which can be used to analyze the effects of cushion motion on the forming process. This thesis is focused on creating an FE model for two dies single cushion sheet metal forming press which can be used to analyze the effects of cushion motion on the contact pressure between the stamping tools and blanks. Using LS-PrePost a model with rigid stamping tools and cushion was created where the two blanks were of different thicknesses. After the model creation LS-DYNA was used for the simulations. The results showed that the cushion is moving in all DOFs and due to this movements, uneven contact pressure distribution is seen on the blanks and stamping tools.