Reduction of the Residual Stresses in a Deep-Drawn Cup by Modifying the Draw Die Profile

Abstract Cylindrical deep drawing has been simulated using the FEM-code Dyna2D and has been analysed experimentally. The FEM simulations show that the residual stresses in the cup wall are mainly caused by the unbending of the material when the material leaves the draw die profile. FEM simulations show that by modifying the draw die profile in such a way that the unbending occurs gradually instead of instantaneously as in conventional deep drawing, a substantial reduction of the residual stresses can be achieved. The modified draw die profile also leads to a substantial improvement in the dimensional accuracy of the deep drawn cup. The experimental findings are in close agreement with the results obtained using FEM.