Macro-structured Deep Drawing Tool Design

João Pedro Coelho Cunha

Key information

Authors:

João Pedro Coelho Cunha (João Pedro Coelho Cunha)

Supervisors:

João Pedro Grosa Magrinho (João Pedro Grosa Magrinho); Maria Beatriz Cipriano de Jesus Silva (Maria Beatriz Cipriano de Jesus Silva)

Published in

November 21, 2024

Abstract

Deep drawing is a production process used to create intricate, hollow components from sheet metal, which is indispensable for industries such as automotive and aerospace. This process yields benefits including high precision, ease of automation, and cost-effectiveness, particularly in the context of mass production. The focus of the process lies in the control of material flow within the die as a result of the load applied by a punch, where friction plays a significant role. Lubricants significantly reduce friction but raise environmental concerns, leading to increased interest in searching for more sustainable alternatives among manufacturers. This dissertation explores the implementation of a macro-structured tool to accomplish lubricant-free deep drawing by modifying the geometry of the tool surfaces in contact with the sheet metal and enhancing the overall process efficiency. Numerical simulations are run to analyse the influence of geometric parameter variations in the macro-structured tool on the process efficiency and the final part quality. The experimental tests provide data on the punch force evolution throughout the process and major and minor strain measurements are taken to calculate the deformation paths of the sheet metal after the process. The numerical-experimental validation and sensitivity analysis confirmed that reducing the contact area in the flange area reduces the friction forces and the friction coefficient between the tool and the material no longer has a significant impact on the process.