Study on the effects of tool design and process parameters on the robustness of deep drawing

Abstract

Abstract. In metal forming manufacturing processes, parameter fluctuations and an incomplete understanding of the process can lead to an undesirable deviation of the product properties from the required specifications and, therefore, affect the robustness of the process. In deep drawing, defects such as cracks and wrinkling can be linked to uncertainties within the process- and tool design parameters. To investigate the combined effects of these parameters on the quality of the finished product, simulation models are used to study the effects of parameter changes on the product quality. With the purpose of studying the effects of significant process and tool design parameters on the deep drawing process, a numerical parameter study is carried out based on a modular tool which allows for an investigation of process parameter variations within an adjustable parameter range of tool radii. While the material draw-in and the maximum punch force are used as quality indicators of the deep-drawing process, it could be shown that the elongation of the absolute length of the finished part can be used as an additional indicator for material thinning when observing the effects of the punch shoulder and die shoulder radii on the process robustness.