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Sheetmetal Forming Analysis

AI-FORM: AI-Based Interactive Multi-Objective Optimization for Sheet Metal Forming

AI-FORM, developed by C3P Engineering Software International Co., Ltd., is the first AI-based interactive multi-objective optimization software specifically designed for sheet metal forming. With over 20 years of industry expertise, it provides an end-to-end solution for the stamping industry, covering:

As industrial demands grow, stamping processes and products become increasingly complex. While CAD/CAE technologies and parallel computing have reduced simulation time, optimizing designs for the best solution remains a key challenge. AI-FORM addresses this with geometry-driven optimization, enabling rapid evaluation of multiple design alternatives to shorten product cycles and enhance quality.

Key Features of AI-FORM

 

1. Technology

  • Geometry-Driven Optimization – Automatically adjusts designs for optimal performance.
  • Fully Automatic Mesh Generation & CAE Model Setup – Reduces manual effort and errors.
  • All Parameters Optimizable – No restrictions on which variables can be tuned.

2. Method

  • AI-Powered Optimization – Leverages the latest AI algorithms for precision.
  • Multi-Objective Optimization – Balances competing design goals (e.g., strength vs. cost).
  • Advanced Analysis Tools – Includes parallel plot analysis and user-defined formulas for custom conditions.

3. Application

  • Supports All Stamping Processes – Versatile for various manufacturing needs.
  • No Programming or Optimization Expertise Required – Accessible to engineers and designers.
  • Seamless CAD Integration – Unlike traditional tools, AI-FORM directly drives CAD models for true optimization.
AI Form Capabilities
AI-Form SPW Hotspot AI-Form SPW Mesh Hotspot

Stamping Process Works (SPW)

The Stamping Process Works (SPW) module is specialized for process planners and tooling designers, enabling rapid creation of stamping process designs and generation of die faces for complete stamping processes.

Key Capabilities

  • Works for both single-stage and multi-stage die designs
  • Widely applied in automotive, electronics, consumer products, and more
  • Generates high-quality connection mesh while ignoring common geometry defects
  • Serves as the default mesher for Form-Advisor batch setup mode

Performance Benefits

10x faster than traditional CAD/CAE mesh-based methods

Enables creation and validation of 4-5 design solutions in a single working day

Workflow Advantage

Process planners can quickly generate multiple tooling concepts and stage plans in early design phases, then seamlessly transfer to CAE systems for validation.

Result: Faster decision-making and optimized stamping processes from the earliest design stages.

Design for Manufacturing (DFM)

FIND CRITICAL REGIONS! IN 3 CLICKS, 3 MINUTES!

AI-FORM DFM is the most powerful upfront Design for Manufacturing tool with innovative technology to quickly identify stamping formability issues and respond to RFQs.

AI-FORM DFM serves as the critical first step in stamping part manufacturing, bridging part designers and manufacturing suppliers with actionable insights.

Key Features & Applications

  • Built-in advanced CAE technology for geometric formability analysis
  • Comprehensive formability assessment with Formability Difficulty Index (FDI) contours
  • FDI guides stamping process planning and die design decisions (including stage numbers for complex drawings)
  • Integrated mesh morphing and smoothing for easy pre-form geometry design
  • Advanced visualization for intuitive result interpretation
  • Customizable FDI formula parameters for specific requirements

Workflow Benefits

With AI-FORM DFM, engineers can:

  • Quickly identify critical forming areas in stamping parts
  • Design optimized pre-form stages using mesh morphing capabilities
  • Make data-driven manufacturing decisions from the earliest design phases
  • Accelerate RFQ responses with immediate formability feedback

Result: Faster, more manufacturable designs with reduced trial-and-error in production.

AI-Form DFMAI-Form DFM
Geo Designer Hotspot Geo Designer Hotspot Geo Designer Hotspot

Knowledge-Based Engineering for Sheet Metal Stamping

AI-FORM's KBE system accelerates die design through feature-based knowledge automation, ensuring right-first-time designs.

Core Capabilities

  • Feature-based technology with object-oriented representation
  • Automated manufacturing feasibility assessment
  • Multi-stage deep drawing design guidance
  • Pre-defined templates for bending, forming, drawing, and stretching
  • Open XML-based system for unlimited customization
[KBE data visualization examples: piercing/shaving process, 90° bending springback]

Stamping Feature Intelligence

AI-FORM's KBE masters complex feature relationships including:

  • Piercing, bending, blanking, drawing
  • Forming, half-cut, ironing, coining
  • Burring and strength features

Feature Study Advantages

  • Quick generation of CAD/analysis models
  • Automatic simulation condition setup
  • Parameter optimization for design standards
  • Direct application to global models

Customization Power

Expand the KBE system by:

  • Modifying geometry and feature parameters
  • Adding custom classes/subclasses via XML
  • Building company-specific design rules

Result: Capture and automate your stamping expertise while reducing design iterations.

Case Study 1: Oil Panel Stamping Optimization

Initial Challenge

Complex shape with uneven drawing depth caused serious wrinkles and cracks during stamping.

Geo Designer Hotspot[Initial simulation showing defects]

Project Background

The oil panel's saddle feature required optimization of:

Traditional trial-and-error CAE methods proved too slow and inefficient.

Optimization Strategy

Geo Designer Hotspot[Schematic of input parameters]

Key variables selected:

Optimization Criteria

Two-Phase Approach

Phase I: Design of Experiments (DOE)

Identified feasible process window

Phase II: Particle Swarm Optimization (PSO)

Precisely located optimal parameters

Geo Designer Hotspot[Parallel coordinates plot of PSO results]

Optimal Solution Found

Geo Designer Hotspot[Final simulation showing defect-free result]

Key Benefits Demonstrated

Case Study 2: CAD-Driven Optimization for Cracking

Initial Challenge

Complex geometric features caused forming difficulties, leading to cracking issues in both simulation and physical try-out.

Geo Designer Hotspot[Initial simulation/try-out showing cracks]

Project Background

Key challenges addressed:

Optimization Approach

1 Blank Shape Improvement

Optimized initial blank configuration

2 Design of Experiments (DOE)

Geo Designer Hotspot[ParaCAD model of die face]

Parametric design of critical dimensions:

  • Key heights H1 and H2
  • Friction factor optimization
  • Drawbead force adjustment

3 Optimal Working Window

Identified parameter ranges for quality production:

  • Friction factor: 0.04 to 0.05
  • H2: -55.0 to 30.0
  • H1: -42 to -10
  • Drawbead force: 0.01 to 0.05
Geo Designer Hotspot[Variable influence proportion diagram]

Final Results

Geo Designer Hotspot[Mass production results and thickness distribution]

Achieved crack-free production within optimized parameter windows

Key Success Factors

AI-Form Feaures

CAD-Driven Optimization: Breaking Traditional Barriers

Most CAD and CAE systems operate independently, relying on inefficient data exchanges. AI-FORM eliminates this gap with its built-in ParaCAD system, allowing:

  • Optimization of any CAD variable, component, or geometry within a unified environment.
  • Real design improvements rather than limited parameter tweaks.

Smart Optimization Parameter Setup

AI-FORM introduces "Equivalent Input" technology, enabling:

  • Optimization of any parameter through standard input fields—no specialized interfaces needed.
  • Unlimited optimization flexibility, overcoming traditional software constraints.

Conclusion

AI-FORM revolutionizes sheet metal forming by integrating AI, CAD, and CAE into a single, user-friendly platform. It empowers manufacturers to reduce design time, enhance quality, and achieve optimal production efficiency—all without requiring advanced programming or optimization expertise.

Ideal for: Stamping engineers, designers, and manufacturers seeking AI-driven, automated, and high-precision forming solutions.

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