Material Point Method‐Based One‐Step Inverse Forming Analysis for Non‐Matching Interfaces

ABSTRACT This paper presents a unified iCPDI2‐based computational framework for one‐step inverse forming of complex sheet metal parts with non‐matching interfaces. The formulation consists of two main stages: A linear elastic reverse deformation stage for initial solution estimation, and an implicit plastic solution stage that accounts for material nonlinearity and predicts the post‐forming distributions of thickness, equivalent strain, and equivalent stress. By introducing an Eulerian background grid as a kinematic mediator, the method decouples the physical domain from the computational domain. The momentum equations defined on the non‐matching physical domain are mapped onto a matching background grid for solution, thereby effectively resolving the challenges associated with non‐matching interfaces in CAE simulations of complex components. The proposed method is validated through three numerical examples. The results show that it achieves high accuracy relative to standard FEM solutions, effectively handles non‐matching interfaces, and accurately predicts the post‐forming distributions of thickness, equivalent strain, and equivalent stress. These findings confirm the effectiveness and robustness of the proposed approach for inverse forming analysis of complex sheet metal components with non‐matching interfaces.