This paper presents a methodology to determine proper temperature levels and zones for successful warm forming of lightweight materials. A comparison of experimental and finite element analysis
(FEA) results is presented to verify the effectiveness of FEA in warm deep drawing and rectangular pan forming processes. A new methodology to determine the proper temperature distribution of tooling and blank was proposed using design of experiments (DOE) and FEA. Results of this method were compared with those of alternative approaches. The proposed method offers alternatives for rapid and relatively accurate predictions and design of warm forming process especially for large parts that require 3D FEA.