Finite Element Simulation of Plug-assist Forming

Abstract A thick sheet analysis of deformation is used to simulate the process of plug-assist forming. The formulation is based on the total Lagrangian description and the equations are solved by the finite element method. The results are in agreement with experimental data available in the literature for sheet thickness distribution and plug force required as a function of deflection. The analysis provides the complete stress and strain fields and may be used to locate regions where fracture may initiate.