Sheet metal forming simulation can help tool and die designers to build tools right the first time, saving large amounts of time and money. In this case, Malbern Engineering in South Africa had designed and fabricated a tool for a new automotive project. During initial tryout, the process formed the part successfully. However, once the tool was set for production, constant splits resulted. Initially, a forming simulation of the current process was performed, to determine if the splits were expected. The forming simulation result shows that indeed, the material is predicted to split. This is due to excessive thinning in the current process. "I decided to modify the 1st stage form tool as per your recommendation and as you can see from the photo’s the proposal was successful. Thank you very much for your input." Marco Smargiasso - Technical & Marketing Manager - Malben Engineering A modification to the pre-form process was proposed, using sheet metal forming simulation to enginee
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