A strain increment method has been proposed for early formability assessment by predicting strain distribution directly from the part-to-part mapping process. This method consists of mapping the finite element mesh to the geometry of an existing part, solving the part-to-part mapping relation by adding bending energy and strain gradient penalty functions, and extracting strain increment from the part-to-part mapping related displacement field. Case studies show that the strain field obtained using the proposed strain increment method compares well with that from the finite element analysis. Since this method does not require the knowledge on new die surface, such formability assessment can serve as an early manufacturing feasibility analysis on the new part design.

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