A disaster in try-out predicted by solid simulation but not by shell
In this simulation of a crossmember made of high strength steel, the toolmaker felt safe after good results in a shell simulation. But in the real process, the part cracks all over the bending radius!
So what went wrong? In solid simulation we can see, that this material has a much too high load in the outer layers of the radiuses, while the neutral fiber is all right.
For brittle high strength steels, the cracked outside leads to a material weakening, so the crack propagates through the component.
That's why for forming of High Strength Steel, we always simulate: