This paper presents a methodology to design optimal forming process parameters of the sleeper fixed reinforcing plate based on the use of computer aided engineering (CAE) technology. The methodology uses Unigraphics software to establish the numerical model and DYNAFORM software to simulate its sheet forming process to determine the feasible process parameters affecting its manufacturability, including whether the mould requires the binder, binder force, friction coefficient, and die fillet radius. The forming limit diagram and the thickness distribution diagram are selected to appraise and analyze the forming results. The orthogonal experiment method is adopted to simulate the design parameters to find out the optimum values for mould design.

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

The forming process of automobile trunk side panel was investigated, using numerical simulation technology, to acquire the feasible process parameters and improve the formability of the product. With the technology, the manufacturability working procedures and drawing process parameters of the product were analyzed, calculated and simulated to achieve optimum formability characteristics. The method effectively lowers the probability of springback, wrinkling and thickness reduction, and shortens design cycle and cost. Based on the simulation results including forming limit diagram and thickness distribution diagram, the feasible process parameters are determined.