Deep drawing is a manufacturing process that can create a complex shape out of a simply shaped plate (blank). The deep-drawing configuration is shown in the figure, which is composed of a blank, punch, die, and blank holder. The thickness of the initial blank is 0.78 mm. The die is fixed throughout the entire process, while the punch moves down by 30 mm to shape the blank. The holder controls the slip of the blank by applying friction force. The fillet radii of both punch and die are 5 mm. After the maximum downstroke of the punch, both the punch and holder are removed. Then, the blank will experience elastic springback. The objective of this project is to simulate the final geometry of the blank after springback.

Model the process using an axisymmetric problem. You many use CAX4R elements. The whole simulation is divided by three steps.

(1) The blank holder is pushed (displacement control) to provide about 100 kN of holding force.

(2) While the blank holder is fixed at the location of step (1), the punch is moved down by 30 mm.

(3) Punch, die, and blank holder are removed so that the blank is elastically deformed by springback. It is possible to change processes.

The following results need to be submitted:

(1) deformed shape plots of five different steps,

(2) graph of radial position vs. radial strain, and

(3) graph of radial position vs. thickness change,

(4) graph of punch displacement vs. punch force, and

(5) comparison of deformed shapes at the maximum stroke and after springback.