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In this paper, the metal flow lines in product design as well as in forging process design are emphasized with typical application examples. The prediction of metal flow lines using metal forming simulation technology is introduced with their characteristics. An experimental study shows that the metal flow lines have great influence on the structural rigidity of the product. We introduce various typical applications including the case of the severely cut metal flow lines during machining especially on the region where the periodically contacting forces are exerted, the case of abnormal distortion of metal flow lines which can cause the broken or ruined metal flow lines due to much elongation or hot shortness due to viscous heating and the case of the macrosegregation region which should be controlled not to be neighboring with the force bearing region. An example of weight reduction of an automobile part considering the improved metal flow lines is also introduced. These typical applications can give the process engineers the insight in conducting the automobile or mechanical parts design as well as in developing their related manufacturing processes.
For mass production of stamped parts which do require complicated in-press operations, it is always advisable to use a progressive press. But it is difficult to choose progressive die if stamped pats need deep drawing and especially they are unsymmetrical. Because unsymmetrical deep drawing parts are very sensitive to the effect of weight during moving next stages, they are hard to be located exactly on die face. Automotive seat side cushion panel is about 80mm high, unsymmetrical and its low edge needs hemming, so it is hard to produce using progressive die. In this paper to adopt progressive stamping for seat side cushion panel, 5 cases of strip bridges are considered to be strong enough to move next stage die exactly by CAE analysis.