Progressive Die Sequence Design for Deep Drawing Round Cups Using Finite Element Analysis

[+] Author and Article Information
Taylan Altan, Nitin Jain, Xiaoxiang Shi

ERC for Net Shape Manufacturing,  The Ohio State University, Columbus, OH 43210

Gracious Ngaile

Department of Mechanical and Aerospace Engineering,  North Carolina State University, Raleigh, NC 27695gngaile@eos.ncsu.edu

Bryan Pax, Brent Harman, Greg Homan

 Pax Machine Works, Celina, OH 45822

J. Manuf. Sci. Eng 128(1), 366-369 (Dec 26, 2004) (4 pages) doi:10.1115/1.2039942 History: Received January 20, 2004; Revised December 26, 2004

A methodology for progressive die sequence design for forming round cups using finite element method (FEM) based simulations is discussed. The process sequence design developed was applied to forming of an automotive part and was compared with the design obtained from past experience. The methodology proposed in this paper has shown that the integration of design experience and FEM simulations can enhance the robustness of the procedure for die design sequence and reduces the die development cost considerably.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

A round cup manufactured using progressive dies (Part A)

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Figure 2

Geometry of part B (blank thickness: 2.15 mm)

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Figure 3

Variation of the punch diameter and wall thinning in progressive forming stages (example part, A)

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Figure 4

Flow chart to determine the design parameters of the first forming stage for part B

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Figure 5

Simulation model

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Figure 6

Location of maximum thinning at the first stage (determines the upper limit of the punch diameter for the next stage)

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Figure 7

Shape of deformed part at each stage for progressive die sequence design

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Figure 8

Comparison of punch diameters predicted by experience based and FEM assisted approaches

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Figure 9

Thickness distribution in the final part predicted by experienced based and FEM assisted approaches

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Figure 10

Comparison of punch corner radii predicted by experience based and FEM assisted approaches



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