Progressive Die Sequence Design for Deep Drawing Round Cups Using Finite Element Analysis

A methodology for progressive die sequence design for forming round cups using finite element method (FEM) based simulations is discussed. The process sequence design developed was applied to forming of an automotive part and was compared with the design obtained from past experience. The methodology proposed in this paper has shown that the integration of design experience and FEM simulations can enhance the robustness of the procedure for die design sequence and reduces the die development cost considerably.