Parametric Finite Element Analysis for a square cup deep drawing process

Purpose: This manuscript deals with the FEA of the sheet metal forming process that involves various nonlinearities. Our objective is to develop a parametric study that can leads mainly to predict accurately the final geometry of the sheet blank and the distribution of strains and stresses and also to control various forming defects, such as thinning as well as parameters affecting strongly the final form of the sheet after forming process. Design/methodology/approach: The main approach of the current paper is to conduct a validation study of the FEM model. In fact, a 3D parametric FEA model is build using Abaqus /Explicit standard code. Numerous available test data was compared to theoretical predictions via our model. Here, several elastic plastic materials low was used in the FEA model and then, they were validated via experimental results. Findings: Several 2D and 3D plots, which can be used to predict incipient thinning strengths for sheets with flat initial configuration, have been presented for the various loading conditions. Unfortunately, most professionals in the forming process, lack this expertise, which is an obstacle to fully exploit the potential of optimization process of metal forming structures. In this study optimization approach is used to improve the final quality of a deep drawn product d by determining the optimal values of geometric tools parameters. Research limitations/implications: This paper is a first part study of a numerical parametric investigation that is dealing with the most influent parameters in a forming process to simulate the deep drawing of square cup (such as geometric, material parameters and coefficient of frictions). In the future it will be possible to get a large amount of information about typical sheet forming process with various material and geometric parameters and to control them in order to get the most accurate final form under particular loading, material and geometric cases. Originality/value: This model is used with conjunction with optimisation tool to classify geometric parameters that are participating to failure criterion. A mono objective function has been developed within this study to optimise this forming process as a very practical user friend manual.