Influence of Punch Radius on Forming Depth in Deep Drawing of SPCC Sheet Materials: A Simulation-Based Study Using ABAQUS

Abstract

In the deep drawing process of SPCC sheet materials, multiple technological factors such as workpiece temperature, blank holder force, and forming level significantly influence both the processing performance and the final product quality. Among these factors, the radius of curvature of the punch plays a critical role in determining the forming depth of the formed components. This study aims to investigate and evaluate the impact of varying punch radii on the forming depth during the deep drawing of cup-shaped parts from SPCC material. Utilizing advanced simulation methods, this research employs ABAQUS, a commercial finite element analysis (FEA) software, to model and analyze the stamping process. ABAQUS's robust capabilities allow for precise simulation of the complex interactions and deformation behaviors inherent in metal forming operations. The simulations are designed to systematically vary the punch radius and observe its effects on the forming depth, capturing detailed stress-strain distributions and identifying potential defect regions. By comparing simulation results with experimental data, the study aims to validate the accuracy of the simulations and ensure their reliability in predicting real-world outcomes. Key findings reveal that smaller punch radii tend to increase localized stresses, leading to deeper forming depths but also a higher risk of material failure. Conversely, larger punch radii distribute stresses more evenly, resulting in shallower forming depths and improved structural integrity of the formed parts. These insights are critical for optimizing punch design and process parameters in industrial applications. This research contributes to the field of sheet metal forming by providing a comprehensive understanding of the relationship between punch geometry and forming performance. The findings offer practical guidelines for manufacturing engineers to enhance product quality and reduce defects in stamped components. Furthermore, the methodology established in this study can be extended to investigate other material types and forming processes, paving the way for broader applications and innovations in metal forming technology.