Deep Drawing of a Cylindrical Cup with Ironing

Nowadays, deep drawing is one of the most important processes for sheet metal forming, once it allows high rate of production with good quality and low cost per part. Within this, cylindrical cups is one of the most widely studied deep drawing process since it allows analysing the effect of different process parameters in phenomena such as earing, springback and ironing. This work analyses the lubricant conditions and the influence of the die dimensions in the deep drawing of a cylindrical cup with ironing in the cups wall. The ironing process typically imposes high contact forces, normal to the surface of the punch and the die, which can lead to the occurrence of galling, particularly for aluminium alloys. The present study considers an AA5754-O aluminium alloy, which is fully deep drawn. The numerical study was complemented with experimental tests, exploring the contribution of the contact between the blank and the tools as well as the conditions induced by the ironing operation.