Author(s)

J.A.J. El-Sayed

Abstract

During metal forming processes, localized metal thickness changes occur. These variations in metal thickness due to formation are usually ignored during the design phase. These metal thickness variations can drastically alter the fatigue life of the produced part due to the high nonlinear nature of fatigue life dependence on the applied stress. This paper presents an analytical approach to account for the fatigue life degradation due to formability localized thickness changes. The application and efficiency of the developed approach is studied using a metal forming case study of an automotive rocker section. 1 Introduction Sheet metal forming is the most common manufacturing process of automotive inner and outer panels. This process is suitable for mass production of sheet metal parts that have complicated geometry. A sheet metal f

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