The Sheet Metal forming is technique that is used by various automotive and aerospace industries now a days. The forming process is an old technique of manufacturing operation, in which metal is formed by a punch and die to convert a flat sheet of material to a part required shape and size without any defect. The current research investigated the energy absorption characteristics of copper sheet metal having different sheet thickness using ANSYS Explicit Solver workbench. The CAD modeling and finite element analysis is conducted using ANSYS software (ANSYS design Modeler). Equivalent Stress(Von-misses Stress), Total Deformation, Internal Energy and Shear stress graphs are generated for the material. Also the FEM model is being optimized using Taguchi Response Surface optimization method. The die length and the die angle are taken into account for optimization. The main results reveled to determine the location and magnitude of stress, pattern of internal energy, deformation.

Keywords : ANSYS, Sheet metal Forming, Energy, CAD, FEM