Development of methodology for inverse forming using LS-Dyna for generating blank shapes

This research was carried out as a part of the ADMRC project "SMARTFORM: Sheet Metal Automated Rapid Tooling for Forming". This project was aimed at developing a software package of the same name that would help the local aircraft manufacturers in Wichita by automating and standardizing the various tasks involved in using FEA to design and troubleshoot sheet metal forming processes. This thesis summarizes various contributions made towards achieving these goals. In particular, we have developed and tested a capability to carry out inverse forming simulations using LS-Dyna. This capability can be used to develop initial blank shapes needed to form parts thereby reducing the number of simulations required to arrive at a feasible forming process. The blank shapes generated compare very well against those obtained from FASTBLANK and QSTAMP, widely used commercial inverse forming packages. Additional capabilities have also been developed to aid the designer in modifying the blank geometry that is obtained from the inverse forming analysis.