Experimental and numerical analyses of carbon steel sheet metal forming process using strain rate dependent friction model

The main objective of this study is to test experimentally and model numerically the forming process of a carbon steel cylinder including deep drawing, walls ironing, and annealing steps. The experimental tests were conducted using two drawing and ironing rings separated by a spacer ring. The geometric modeling of various stages of formation was conducted by applying the finite element method (FEM). The results obtained from the finite element model were compared and verified with the experimental tests. The output results showed a good agreement with the experimental tests. In addition, the effects of the forming parameters such as drawing speed on residual stresses and drawing force and cup height were investigated through FEM in two friction modes: strain rate-dependent coefficient of friction model and constant coefficient of friction. The results show that the coefficient of friction has a major effect on the drawing force and the wall thickness reduction.