Abstract
Abstract The solid bosses are an important construction of light weight components, which have widely used in automobile and electronic industries. In this paper, the solid boss was formed by the combined compression and deep drawing process based on plate forging method. The finite element method (FEM) with DEFORM-2D was used to investigate the solid boss forming process, and a dimple defect model induced by stress bending moments was proposed. The results show that the evolution of dimple depth would be divided into three stages in the solid boss forming process, which can be descripted as a process of occurrence, disappearing and growing up a dimple. The FEM predictions agree with the theoretical calculations.
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