Problems of multi-step forming sheet metal process design

This paper describes a numerical simulation of the deep-drawing process of the multi-operational forming of a compressor cover and its optimization by FEM simulation. Several modified tools were tested by simulation and optimized tool shapes from the point of view of minimum number of operations and optimum thickness changes of the sheet at each stage of metal forming were found. The application of FEM into the metal forming processes is a powerful tool for more economical design and reducing costly trial-and-error processes.