Abstract
This paper deals with a manufacturing process for sheet metal components with integrated functional elements by sheet–bulk metal forming. In a single forming stage a cup-shaped base body with thin-walled features is deep drawn and its geometry is calibrated by upsetting. The fundamental numerical and experimental investigations include the analysis of the die filling behaviour, part geometry and mechanical properties due to strain hardening with respect to the variation of the blank layout, forming force and material strength. Finally, the process limits are identified and approaches for their enhancement by the application of tailored surfaces are presented.
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