Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study
Deep-drawn components are predominantly manufactured using multistep operations, e.g., in a progressive or transfer dies. Currently, intermediate die design is geometry-based and often neglects the influence of workpiece plastic flow during forming on the final part's mechanical performance. Th...
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| Format: | Article |
| Language: | English |
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EDP Sciences
2025-01-01
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| Series: | MATEC Web of Conferences |
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| Online Access: | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01085.pdf |
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| _version_ | 1850267841588101120 |
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| author | Marín Gabriel Weber Florian Sulaiman Hosen Heuse Martin Korkolis Yannis P. |
| author_facet | Marín Gabriel Weber Florian Sulaiman Hosen Heuse Martin Korkolis Yannis P. |
| author_sort | Marín Gabriel |
| collection | DOAJ |
| description | Deep-drawn components are predominantly manufactured using multistep operations, e.g., in a progressive or transfer dies. Currently, intermediate die design is geometry-based and often neglects the influence of workpiece plastic flow during forming on the final part's mechanical performance. This approach results in non-homogeneous material deformation, inefficient material utilisation, wrinkling defects, and an increased risk of service failures. This study proposes an alternative workpiece-performance-based die-design approach for deep drawing, emphasising the critical role of material flow in determining the component's geometrical accuracy and mechanical properties. The strategy was experimentally tested on S420MC steel (1.8 mm thickness) square cups using two-step process chains: (1) a conventional method where the blank was partially drawn into a square cup, followed by full drawing, and (2) an alternative method starting with a circular blank partially drawn into a circular cup before full drawing to the square shape. Numerical analysis in AutoForm evaluates the evolution of effective plastic strain throughout the steps. The results demonstrate significant improvements, including more uniform strain distribution, a 7% wall thinning reduction, elimination of ironed wrinkles, and components with threefold increased strength and enhanced ductility. These findings highlight the potential of performance-based die design to improve material efficiency and structural reliability. |
| format | Article |
| id | doaj-art-43c3b795c91241d3992b0f02f5b3edbb |
| institution | OA Journals |
| issn | 2261-236X |
| language | English |
| publishDate | 2025-01-01 |
| publisher | EDP Sciences |
| record_format | Article |
| series | MATEC Web of Conferences |
| spelling | doaj-art-43c3b795c91241d3992b0f02f5b3edbb2025-08-20T01:53:37ZengEDP SciencesMATEC Web of Conferences2261-236X2025-01-014080108510.1051/matecconf/202540801085matecconf_iddrg2025_01085Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary studyMarín Gabriel0Weber Florian1Sulaiman Hosen2Heuse Martin3Korkolis Yannis P.4Institute of Forming Technology and Lightweight Components, TU DortmundInstitute of Forming Technology and Lightweight Components, TU DortmundFaurecia Autositze GmbHFaurecia Autositze GmbHInstitute of Forming Technology and Lightweight Components, TU DortmundDeep-drawn components are predominantly manufactured using multistep operations, e.g., in a progressive or transfer dies. Currently, intermediate die design is geometry-based and often neglects the influence of workpiece plastic flow during forming on the final part's mechanical performance. This approach results in non-homogeneous material deformation, inefficient material utilisation, wrinkling defects, and an increased risk of service failures. This study proposes an alternative workpiece-performance-based die-design approach for deep drawing, emphasising the critical role of material flow in determining the component's geometrical accuracy and mechanical properties. The strategy was experimentally tested on S420MC steel (1.8 mm thickness) square cups using two-step process chains: (1) a conventional method where the blank was partially drawn into a square cup, followed by full drawing, and (2) an alternative method starting with a circular blank partially drawn into a circular cup before full drawing to the square shape. Numerical analysis in AutoForm evaluates the evolution of effective plastic strain throughout the steps. The results demonstrate significant improvements, including more uniform strain distribution, a 7% wall thinning reduction, elimination of ironed wrinkles, and components with threefold increased strength and enhanced ductility. These findings highlight the potential of performance-based die design to improve material efficiency and structural reliability.https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01085.pdfdeep-drawingstrain distributiontool designperformance enhancement |
| spellingShingle | Marín Gabriel Weber Florian Sulaiman Hosen Heuse Martin Korkolis Yannis P. Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study MATEC Web of Conferences deep-drawing strain distribution tool design performance enhancement |
| title | Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study |
| title_full | Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study |
| title_fullStr | Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study |
| title_full_unstemmed | Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study |
| title_short | Design of multi-step dies for sheet metal forming using a workpiece-performance-based approach: A preliminary study |
| title_sort | design of multi step dies for sheet metal forming using a workpiece performance based approach a preliminary study |
| topic | deep-drawing strain distribution tool design performance enhancement |
| url | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01085.pdf |
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