This paper introduces a CAE-based design procedure in the press forming process for the fabrication of sheet metal parts used in proto-cars. The finite element analysis reveals formability problems during the forming process of a floor member and a front cross member that constitute a rear floor assembly. The study proposes the modification of the initial blank shape or intermediate trimming of the product to prevent failure during forming. It is confirmed by the tryout process as well as the finite element analysis that sound prototype can be obtained with the modified design. The finite element analysis result also provides fairly good prediction of springback amounts used for the post-compensation of the product.
