Incremental sheet metal forming: Numerical simulation and rapid prototyping process to make an automobile white-body

In order to make an automobile body structure, incremental sheet metal forming is introduced as a rapid prototyping process. Numerical modeling of the process is initially used to predict the deformation of the sheet metal to avoid failure during the incremental forming process using ABAQUS/Explicit finite element code and OYANE's ductile fracture criterion via a VUMAT user material. An automobile CAD model is then designed, and segmented into several parts in order to accommodate the working space of the CNC machine and formability of sheet metal. After that, CAM software is used to generate a tool-path for making wooden-dies and all small parts. Finally, a welding process is applied to join all parts which were cut by laser cutting after incremental sheet forming process.