A COMPARATIVE STUDY ON DEEP DRAWING PROCESS AND AUTOFORM SIMULATIONS OF DX54D + Z and DX56D + Z STEELS

Abstract

A Sheet Metal Forming (SMF) process, especially deep drawing, is one of the manufacturing processes that commonly used in the automotive industry. Compared with casting and forging, the SMF process has several advantages, including lesser weight materials and broader variations in shape that can be made. The most important of the problems in the SMF process is the wrinkling phenomenon and tearing of sheet products. The wrinkle and tear occurs because of the mechanical properties of the material, product geometry, and blank holder force. The finite element based Computer-Aided Engineering (CAE) program AutoForm Plus R7 used in this article was used for analysis. Solidworks software was used during mold design. AutoForm is a highly productive software that provides high accuracy and reliable results, specially developed for the sheet metal forming mold industry, especially for the automotive industry. With AutoForm, multiple analyses were made by computational calculations, even before the mold production started, and with the help of these analyses, the closest to perfect mold outputs were obtained. In addition, optimum drawbead geometry and springback effect were analysed. The most suitable material was selected for the deep drawing product. DX54D + Z and DX56D + Z from continuously hot-dip coated steel flat products selected as analysis materials. As a result, the simulation reports obtained from this study were compared with many results in the literature. It is concluded that DX56D + Z sheet material can be used in deep drawing products without negative consequences such as tearing, wrinkling and shrinkage marks.