Numerical analyses of the influence of a counter punch during deep drawing

authored by: Bernd Arno Behrens, Daniel Rosenbusch, Hendrik Wester, Joshua Weichenhain, Philipp Althaus
Abstract: In the automotive sector, the demand for high crash safety and lightweight construction has led to an increased use of steels with higher strengths. However, the rising number of varying materials with different strengths and ductilities lead to an increasing complexity in productionmaking it more challenging to ensure robust processes. Therefore, the focus of current researches still lays on the further development and extension of forming processes to enable high productivity and reliable production. A powerful tool for an efficient optimisation and extension of forming processes is the Finite Element Method (FEM), which offers time-and cost saving potentials in the design phase. In deep drawing, the use of a counter punch offers the possibility oextending the process limits. By superimposing compressive stresses on the workpiece, the initiation of cracks can be delayed, thus higher drawing ratios can be achieved. The aim of this research is therefore the numerical investigation of a deep drawing process with a counter punch to analyse the influence on the crack initiation and identify optimisation potentials for the processFor this cause, the applied force as well as the position and geometry of the counter punch are varied and the influence on fracture initiation is evaluated. It is found that the applied force on the counter punch is the major influencing factor for crack initiation. Furthermore, it was concluded that the contact between the counter punch and the workpiece should be applied as soon as the bottom of the cup is shaped. A further improvement can be achieved if the counter punch is geometrically adapted to the bottom of the workpiece.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Pages: 329-336
No. of pages: 8
Publication date: 2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all)
Electronic version(s): https://doi.org/10.21741/9781644902417-41 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{abcbbb9aefda4a379ff24c77d95e9048,
title = "Numerical analyses of the influence of a counter punch during deep drawing",
abstract = "In the automotive sector, the demand for high crash safety and lightweight construction has led to an increased use of steels with higher strengths. However, the rising number of varying materials with different strengths and ductilities lead to an increasing complexity in productionmaking it more challenging to ensure robust processes. Therefore, the focus of current researches still lays on the further development and extension of forming processes to enable high productivity and reliable production. A powerful tool for an efficient optimisation and extension of forming processes is the Finite Element Method (FEM), which offers time-and cost saving potentials in the design phase. In deep drawing, the use of a counter punch offers the possibility oextending the process limits. By superimposing compressive stresses on the workpiece, the initiation of cracks can be delayed, thus higher drawing ratios can be achieved. The aim of this research is therefore the numerical investigation of a deep drawing process with a counter punch to analyse the influence on the crack initiation and identify optimisation potentials for the processFor this cause, the applied force as well as the position and geometry of the counter punch are varied and the influence on fracture initiation is evaluated. It is found that the applied force on the counter punch is the major influencing factor for crack initiation. Furthermore, it was concluded that the contact between the counter punch and the workpiece should be applied as soon as the bottom of the cup is shaped. A further improvement can be achieved if the counter punch is geometrically adapted to the bottom of the workpiece.",
keywords = "Fracture Analysis, High Strength Steel, Process Extension",
author = "Behrens, {Bernd Arno} and Daniel Rosenbusch and Hendrik Wester and Joshua Weichenhain and Philipp Althaus",
note = "Funding Information: The results presented were obtained in the project “Extension of the forming limits during deep drawing by additional force transmission” – 212270168. The authors thank the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG) for their financial support.; 20th International Conference on Sheet Metal, SHEMET 2023 ; Conference date: 02-04-2023 Through 05-04-2023",
year = "2023",
doi = "10.21741/9781644902417-41",
language = "English",
isbn = "9781644902400",
series = "Materials Research Proceedings",
publisher = "Association of American Publishers",
pages = "329--336",
editor = "Marion Merklein and Hinnerk Hagenah and Duflou, {Joost R.} and Livan Fratini and Fabrizio Micari and Paulo Martins and Gerson Meschut",
booktitle = "Sheet Metal 2023 - 20th International Conference on Sheet Metal",
}