Design solution evaluation for metal forming product development

In the current metal forming product development paradigm, the simultaneous and optimal design of product, process and forming system is a non-trivial issue as there are many affecting factors which interact and interplay each other. In the up-front design process, the systematic evaluation and verification of design solution is critical as this could shift the product development paradigm from traditionally trial-and-error and heuristic know-how to more scientific calculation, analysis and simulation. To ensure the efficient and accurate assessment and evaluation of design solution generation, state-of-the-art technologies need to be developed. In this paper, a methodology for systematic evaluation and verification of the simultaneous design of metal forming product, process, and forming system is presented. The factors which affect these designs are first articulated and how they interact and interplay are described. The importance of the systematic evaluation of designs is, thus, figured out. In addition, the role that CAE simulation plays in this process is explained. To evaluate the design, detailed evaluation criteria are developed and how the criteria are used through CAE simulation technology to reveal the behaviors and performances of designs is articulated. Through case studies, the developed technology is illustrated and its efficiency is finally verified.