Minimizing the drawing stages of a Bracket Assembly Upper Spring using DYNAFORM

This research work deals with the formability of sheet metal parts that depends very much on material properties, machine and process parameters, and part geometry. It provides an insight into drawing of low carbon steel axis-symmetrical cylindrical cup known as Bracket Assembly Upper Spring using DYNAFORM in order to reduce the current four draw stages. The simulation process is analyzed through finite element analysis (FEA) solution that generates the forming limit diagram (FLD) of the part as well as the stress, strain and thickness results. In this paper, the results of the optimization process showed that the risk of the part to form cracks is lesser than the actual part produced by the company. The percentage away from the failure zone of the FLD is higher than the current draw stages. In addition, the minimum thickness of the part produced is still within the acceptable quality control limits.