Efficient simulation of ironing process for deep drawn parts

International Deep Drawing Research Group 37th Annual Conference

Gösling, M.^1 ; Güner, A.^2 ; Burchitz, I.^3 ; Thülig, Th.^1 ; Carleer, B.^2

BILSTEIN GmbH and Co. KG, Im Weinhof 36, Hagen

58119, Germany^1

AutoForm Engineering, Joseph-von-Fraunhofer-Straße 13a, Dortmund

44227, Germany^2

AutoForm Engineering B.V., Industrieweg 2, LB Krimpen a/d IJssel

NL-2921, Netherlands^3

关键词: Automotive component;    Automotive stamping;    Computational costs;    Efficient simulation;    Layer compression tests;    Stamping operations;    Thickness direction;    Thickness distributions;   

Others  :  https://iopscience.iop.org/article/10.1088/1757-899X/418/1/012116/pdf
DOI  :  10.1088/1757-899X/418/1/012116

来源: IOP

【 摘 要 】

In deep drawing of automotive components, the thickness distribution of the workpiece is a major concern regarding the feasibility of the process. A major geometrical parameter regarding the thickness distribution is the clearance between the punch and the die. The general industrial convention regarding this clearance is to use the initial blank thickness combined with a tolerance. This approach assures that the sheet is not compressed in the thickness direction which leads to undesired or undefined deformations and also high forces. Nevertheless, deformation in the thickness direction during stamping operations can be desired or advantageous in some cases. For instance, in flanging operations, ironing is used to reduce springback. There are already applications using solid elements for modelling such operations but these simulations are industrially not relevant due to high computation times. Currently, there is a need for an efficient simulation solution using shell elements. In order to address this problem, the shell element formulation was enhanced by taking the through-thickness deformation into account. In order to verify the new formulation, cup drawing experiments were performed using three different degrees of ironing. The material was a DC04- SUPERMOD with 1.75 mm thickness that was characterized by tensile tests in three directions, a bulge test and a layer compression test. Numerical and experimental results were compared in terms of the thickness distribution along the cross-section and the cup heights. Results show that the ironing process, which occurs in automotive stamping parts, can be simulated with enhanced shell elements without significant additional computational cost.