Abstract: An acceptable approach to generate a 3D forming path, which is called virtual guiding model method is accomplished. The method has the similar idea with the conventional COPY mill. A track ball is forced to move continuously on a virtual guiding tool which is generated from the part to simulate the real moving process of the forming tool. Based on the idea and the simple principle of kinematics, the FEM model of the track ball and the virtual guiding tool is constructed. Through the analysis of the computing process, the suitable loading force and forming velocity are ascertained, and the influence factors of the computing precision are also discussed. Because the method is based on FEM simulation completely, the generated forming path can be used directly for the subsequent metal blank forming process. This method is realized in the FEM software PAM-STAMP and mainly used in the simulation of the sheet metal incremental forming process.

Key words: Blank sheet, FEM, Incremental forming, Space movement