Abstract: A mechanical model and its solution for the cold metal sheet forming with rigid elliptical punch and deformable die is proposed to study these problems in details, some practical forming examples are investigated. According to interactive states of the forming sheet with the foundation and the punch, the sheet may be devided into three parts, and corresponding equlibrium equations analytical solutions are derived by large deflection plate theory and contact mechanics. Numerical efforts is made for distributions of internal forces and contact stresses of the sheet by relative compatibility conditions and interation approach. The present model is featured with less assumptions and computational effort the others.

Key words: Cold sheet forming, Elastic-plasticity Beam bending, Nonlinear plate theory, FDM, Micro/meso scale gas foil bearings, Slip flow, Static and dynamic performance