Optimizing Reverse-Engineered Finite Element Models for Accurate Predictions of Experimental Measurements

Abstract This study investigates the challenges of reverse engineering in finite element modelling of sheet metal forming, specifically for the Volvo XC90 front door inner component. Advanced models incorporating anisotropic behaviour of steel and non-linear friction are compared against actual real-world measurements. The methodology involves simplifying complex continuous parameters into more manageable representative data sets and assessing model accuracy under both uniform and varied blank holder force settings, guided by measured contact pressure distributions. Although the results indicate an improvement in accuracy, they underscore the need for additional methodological improvements and more accurate replication of tooling effects to enhance the fidelity and effectiveness of these models.