StampFormer: A Physics-Guided Material-Geometry-Coupled Multimodal Model for Rapid Prediction of Physical Fields in Sheet Metal Stamping

Abstract

Traditional sheet metal forming relies on time-consuming and expensive Finite Element Analysis (FEA) for design validation, a process that significantly prolongs design cycles. While surrogate models offer faster iteration, current approaches have limitations: scalar-based methods cannot capture comprehensive field-based FEA results, while existing image-based models often ignore the critical role of material properties by focusing solely on geometry. To address this gap, we develop a physics-guided deep learning framework, namely StampFormer, which simultaneously uses component geometry and material stress-strain responses to predict FEA outcomes. The StampFormer framework uses three core components to process data. A Material-Augmented Geometric Network (MAGN) first fuses geometric and material data. This information is then integrated at various levels by a Hierarchical Material Embedding Injection Unit (HMEIU) before being processed by the primary network backbone, an adapted Swin-UNet. We evaluated our model on the stamping of a crossmember panel with two simulation datasets for steel and aluminium panels, and results demonstrate that StampFormer provides high-fidelity predictions of critical physical fields - including thinning, major strain, minor strain, plastic strain, and displacement - in under a second. Compared with ground truth FEA, our model achieved an average relative error of less than 8.5% on the four 2D fields and a mean squared error of less than 1.2 mm2 for the 3D displacement field. In summary, we introduce a practical and efficient framework that integrates multimodal information, namely geometry and material properties, to provide fast and accurate predictions, enabling designers to perform real-time manufacturability assessments.