The optimization of die design in deep drawing process with finite element method

Deep drawing is a sheet metal forming process that is used to produce the container shaped parts. Deep drawing process is very popular in industry because its high production rate, low cost andwide product range. Deep drawing that is the subject of many studies is very complex process due to high number of parameters. There are a lot of parameters which affect the quality of finished product such as punch stroke, punch speed, blank holder force, die radius, punch radius, clearance and drawing rate.In addition, the computer aided calculation software are essential for detailed results since the determination of the forces and stressesare very difficult. Therefore, the simulations are generated with ANSYSsoftware which solves the problems with the finite element method in this study.The examined parameters are punch speed, blank holder force, die radii and punch radii in the conducted research. The number of simulation is reduced from 81 to 9 with Taguchi experiment design method because of the high number of simulations. In this study, the effects of those parameters on the minimum thickness, maximum thickness and maximum stress of the finished product are observed. The optimum parameter values are determined according to obtained results. Key Words: Deep Drawing, Die Design, Optimization, FEM, Taguchi