Process development of aluminium ironing using finite element analysis

Abstract

In this paper, the use of finite-element simulation of an aluminium ironing process is presented. In this process friction, clearance distance between punch and die and punch radius must all be taken into consideration when designing products and processes. In practice, it is difficult to analyse individual parameters separately, but with computer simulation it is easy to see the effects of changing one specific parameter on the outcome of the process. This work has demonstrated the use of computational support in product development to gain an understanding of the effects of process and geometric parameters. The most important results were confirmation of the sensitivity of the process to clearance distance between punch and die and, also, frictional conditions, as well as the relative insensitivity of the process to change in punch nose radius.