Abstract: Numerical simulation on forming process of Alto car fender is introduced to optimize parameters. Structure elements of cover panel and the index library of similar event are set up based on the experience knowledge and the similarity theory．The complementary surface is built through the method of index of similar event ，the position of draw bead and stamping direction and others process parameters are made certain at the same time．The mesh deformations of forming process are dynamically showed and a lot of information including FLD, distributions of stress, strain and thickness are also related. Binder force and shape of draw bead are opti- mized；the die is made and the forming test of Alto car fender is completed by the simulation result. The experiment results show that the simulation and parameter optimization based on experience knowledge can be used to direct practical production and can be used to reduce production cycle and material consumption.

Key words: Cover panel, Experience knowledge, Numerical simulation, Parameter optimization, Similarity theory