Analytical and Numerical Simulation of Deep Drawing and Ironing

The prediction of earing and wall thickness distribution in cylindrical deep drawing is a challenging task even for today’s FEA programs with advanced yield loci. The current work involves an analytical description of cylindrical deep drawing that is comparable in accuracy to advanced numerical models. The analytical approach shows the importance for these type of simulations of fitting the yield locus description to test results in multiple directions, and the limitations in earing prediction due to the inaccuracy of these tests. A consecutive ironing operation poses additional challenges, in particular for shell elements in FE simulations, due to through thickness stress. The applicability of a new shell option in Pam‐Stamp 2G is demonstrated for this situation.