Analysis of Springback Effects in Deep Drawing Processes: Simulation and Experimental Studies

Manufacturing of parts with consistent dimensions and minimized process variations are among the greatest challenges in deep drawing operations. In this regard, springback which is a phenomenon created when the residual energy generated during forming process causes change in final part dimensions and geometry when released from the tooling system. There are many parameters affecting springback; they can be generally classified as design parameters, material properties and process variables. This paper deals with identifying relative importance of these parameters and their contribution in springback. Also, it reports on the results of a simulation study of the process and its comparison with the experimental results. A test setup is designed and developed that is utilized in experimental study of the process and analysis of relevant data as reported in this article. Finite element model of the process is developed and used in simulation study of the process. The results of simulation and those obtained from experiment are compared and the results are presented. Finally, the impact of different process parameters on springback are studied in details. Design of Experiment (DoE) is used as a tool to systematically analyze and rank contribution of different parameters on springback and the results are presented.