Reduction of forming steps of an axisymmetric multi-step drawing problem via numerical modeling

An automotive part formed by 10-step drawing has been simulated by finite element method aiming to reduce forming steps. The reduction of forming steps can be achieved by optimum design of tooling shapes and other process parameters per each step. The ultimate goal will be to apply the derivative based optimization scheme or any knowledge-based system to these kinds of multi-step forming problems. However, as an initial step, we determined the minimum forming steps and optimum tooling shapes using heuristic manner, insight, design rules and testing with finite element analysis incorporated with a damage model. As a result, the 10-step drawing is reduced to 6-step drawing as a practical optimum solution.