Finite element simulation of ironing process under warm conditions

Metal forming is one of the most important steps in manufacturing of a large variety of products. Ironing in deep drawing is done by adjusting the clearance between the punch and the die and allow the material flow over the punch. In the present investigation effect of extent of ironing behavior on the characteristics of the product like thickness distribution with respect to temperature was studied. With the help of finite element simulation using explicit finite element code LS-DYNA the stress in the drawn cup were predicted in the drawn cup. To increase the accuracy in the simulation process, numbers of integration points were increased in the thickness direction and it was found that there is very close prediction of finite element results to that of experimental ones.