Finite Element Inverse Analysis of an S-rail Forming Process with Direct Mesh Mapping Method and Crash Analysis considering Forming Effects

직접격자 사상법을 이용한 S-rail 성형공정의 유한요소 역해석 및 성형효과를 고려한 충돌해석

The automotive industry have made an effort to reduce the weight of vehicle structures with increased safety, while initial model of the final product does not contain any prehistoric effects in a design stave. It takes lots of time to calculate forming effects that have great influences on the energy absorption of structures. In this paper, finite element inverse analysis is adopted to calculate forming effects, such as thickness variation and effective plastic strain as well as an initial blank shape with small amount of computation time. Crash analysis can be directly performed after inverse analysis of the forming process without remeshing scheme. The direct mesh mapping method is used to calculate an initial guess from the sliding constraint surface that is extracted from the die and punch set. Analysis results show that energy absorption of structures is increased with consideration of forming effects and finite element inverse analysis is usefully applicable to calculate forming erects of vehicle structures for the crash analysis.