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Model validation has become an increasingly important issue in the decision-making process for model development, as numerical simulations have widely demonstrated their benefits in reducing development time and cost. Frequently, the trustworthiness of models is inevitably questioned in this competitive and demanding world. By definition, model validation is a means to systematically establish a level of confidence of models. To demonstrate the processes of model validation for simulation-based models, a sheet metal flanging process is used as an example with the objective that is to predict the final geometry, or springback. This forming process involves large deformation of sheet metals, contact between tooling and blanks, and process uncertainties. The corresponding uncertainties in material properties and process conditions are investigated and taken as inputs to the uncertainty propagation, where metamodels, known as a model of the model are developed to efficiently and effectively compute the total uncertainty/variation of the final configuration. Three model validation techniques (graphical comparison, confidence interval technique, and [r.sup.2] technique) are applied and examined; furthermore, strength and weakness of each technique are examined. The latter two techniques offer a broader perspective due to the involvement of statistical and uncertainty analyses. The proposed model validation approaches reduce the number of experiments to one for each design point by shifting the evaluation effort to the uncertainty propagation of the simulation model rather than using costly physical experiments.

Model validation has become a primary means to evaluate accuracy and reliability of computational simulations in engineering design. Because of uncertainties involved in modeling, manufacturing processes, and measurement systems, the assessment of the validity of a modeling approach must be conducted based on stochastic measurements to provide designers with confidence in using a model. A generic model validation methodology via uncertainty propagation and data transformations is presented. The approach reduces the number of physical tests at each design setting to one by shifting the evaluation effort to uncertainty propagation of the computational model. Response surface methodology is used to create metamodels as less costly approximations of simulation models for the uncertainty propagation. Methods for validating models with both normal and nonnormal response distributions are proposed. The methodology is illustrated with the examination of the validity of two finite element analysis models for predicting springback angles in a sample flanging process.

Byline: Thaweepat Buranathiti, Jian Cao In many manufacturing processes involving sheet metal fabrications, springback is a major concern, complicating tooling designs. This paper develops an effective analytical model to predict springback for a straight flanging process. The model calculates the final springback angle by conducting bending moment computation, geometry and configuration calculation, and springback calculation. The predicted results are examined against our own experimental data and experimental results from independent papers. The predicted results show a good agreement with the corresponding experimental results published in the literature. Sensitivity and trend analysis of springback are efficiently obtained.