Experimental and numerical prediction on square cup punch-die misalignment during the deep drawing process

Punch-die misalignment is one of the factors that can contribute to drawn cup defects such as thinning and tearing. Deep drawing is a closed-die process, and defects can be identified only after the drawing is finished. In this work, the effect of punch-die misalignment severity on the drawing force and wall thickness distribution of electrolytic zinc-coated steel blank (SECC) was investigated. The stress-strain diagram and forming limit diagram of SECC material was determined and simulated using the Hill'48 model. Two conditions of punch-die misalignment were studied: single-axis and multi-axis misalignment. A high punch-die misalignment severity contributes to the increment in the drawing force. Furthermore, wall thickness distribution becomes non-uniform, and the thinning pattern increases due to the greater misalignment severity. For validation, an experiment was conducted on a universal tensile machine.

Automated summary

This study investigates the impact of punch-die misalignment on the drawing force and wall thickness distribution of electrolytic zinc-coated steel blanks. It was found that a higher severity of misalignment results in increased drawing force, non-uniform wall thickness distribution, and greater thinning patterns.