What shell simulation hides - solid simulation reveals bending failure!
For this cross member made of high-strength steel, the process planning team felt confident after good results in a shell simulation. But in reality, the part fails along the entire bending radius.
A detailed solid simulation with Stampack Xpress uncovers the truth: the outer surface is under excessive stress, while the mid-plane remains almost unloaded. Especially with high-strength steels, this damage leads to bending failure that propagates through the entire component.
That’s why we always simulate high-strength steel forming with: