Development and application of finite element simulation software for sheet stretch forming

The stretch forming of aircraft skin components with complex curved surfaces and high-precision requirements poses significant challenges for conventional simulation methods. These techniques exhibit notable limitations, including inadequate accuracy due to mechanism coupling, insufficient wrinkling prediction, and poor integration of CAD and CAE modules. To address these issues, this paper proposes an integrated optimisation approach based on AI-FORM software. By deeply integrating CAD and CAE models, this method achieves multi-dimensional collaborative optimisation of die geometry, process design, and process parameters. It establishes a multi-objective evaluation system covering metrics such as wrinkling, rupture, and springback. Innovatively, It integrates jaw trajectory planning and 2D/3D simulation to address challenges in designing trajectories for complex curved parts. This approach enables comprehensive and efficient skin stretch forming simulation, providing an effective digital solution for high-precision forming of aerospace sheet metal components.