In-Situ-measurement of restraining forces during forming of rectangular cups

Abstract

This contribution introduces a new method for evaluating the restraining forces during forming of rectangular cups with the goal of eliminating the disadvantages of the currently used scientifically established measurement procedures. With this method forming forces are measured indirectly by the elastic deformation of die structure caused by locally varying tribological system. Therefore, two sensors were integrated into the punch, which measure the restraining forces during the forming process. Furthermore, it was possible to evaluate the effects of different lubricants showing the time dependent trend as a function of stroke during the forming of the materials DP600 and DC04. A main advantage of this testing method is to get real friction corresponding data out of the physical deep drawing process as well as the measurement of real acting restraining forces at different areas of the deep drawing part by one single test. Measurement results gained by both sensors have been integrated into LS-Dyna simulation in which the coefficient of friction was regarded as a function of time. The simulated and deep drawn parts afterwards are analysed and compared to specific areas with regard to locally measured thickness of part. Results show an improvement of simulation quality when using locally varying, time dependent coefficients of friction compared to commonly used constant values.