A numerical algorithm is developed to simulate the deformation behaviors of a sheet from the simple axisymmetric to the complex three dimensional geometries. This algorithm employs finite element method with the total Lagrangian approach. It is possible to obtain thickness, stress and strain distribution of each loading step in thermoforming process using this algorithm. The change of various processing conditions such as temperature, plug assists are very crucial to the final deformation behaviors of sheet, and these effects are discussed in this paper.
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