Analysis of an axisymmetric deep-drawn part forming using reduced forming steps

Numerical simulations have been widely used to assist part and process design. In this paper, deep-drawing processes of an axisymmetric part with a complex geometry are analyzed with the aim of reducing possible forming steps. The existing practice requires a 10-step drawing. Our approach combines a optimization scheme, design rules and numerical tests using the finite-element analysis incorporated with a damage model. As a result, the 10-step drawing is reduced to a 6-step drawing. Additionally, the new process design yields a lower maximum void volume fraction in the sheet, meaning a more formable process and a slightly higher press load.