Formability improvement and blank shape definition for deep drawing of cylindrical cup with complex curve profile from SPCC sheets using FEM

In the current work, to predict and improve the formability of deep drawing process for steel plate cold rolled commercial grade (SPCC) sheets, three parameters including the blanking force, the die and punch corner radius were considered. The experimental plan according to Taguchi's orthogonal array was coupled with the finite element method (FEM) simulations. Firstly, the data from the test of stress-strain and forming limit curves were used as input into ABAQUS/Explicit finite element code to predict the failure occurrence of deep drawing process. The three parameters were then validated to establish their effects on the press formability. The optimum case found via simulation was finally confirmed through an experiment. In order to obtain the complex curve profile of cup shape after deep drawing, the anisotropic behavior of earring phenomenon was modeled and implemented into FEM. After such phenomenon was correctly predicted, an error metric compared with design curve was then measured.