Advanced High Strength Steel (AHSS) forming dies are subject to higher forces during stamping. The ability to withstand these loads is largely dependent on the die material and the physical dimensions and shape of the die structure. The accurate prediction of the deflections and stresses of the cast die components are critical to ensuring that dies function properly and do not fail. A common method of analyzing die component behavior is the use of finite element analysis (FEA). Validating FEA models with experimental data gives confidence in accurately predicting behaviors.

In this investigation, experiments were conducted to validate FE models of large cast automotive die components. Deflection was measured and correlated with an FEA linear static analysis. A convergence study was performed to determine the proper number of elements needed for modeling dies. Results indicate that good correlation between FEA and experimental results is possible, provided the model has at least the required minimum number of elements and that the elements are properly formed.

FEA models of stamping dies were further validated by comparing measured reaction forces to those predicted by forming simulation models. Die failure analysis showed good correlation between predicted and actual failure behaviors. Die handling forces were also considered. Finally, existing topology optimization methods were used to derive an improved die design concept.