Deep Drawing simulation of metals - What and how it works

DEFORM Benefits

Quality improvement
Optimization and saving in the design
Improvement of production
Enhanced precision
Flexibility of use
Reduction of calculation times
Reduction of production rejects
Saves money

Deep Drawing: What it is

Deep drawing is a metallurgical process through which sheet metal is plastically deformed to take on a cylindrical or cup like box shape. These operations are carried out using a punch which pushes the sheet metal, possibly secured by a blank holder, into a die. The component is formed through elongation of the sheet metal reducing its thickness during the process.

MORI 2A SPA success story: Deep drawing with DEFORM software.
The thermal, tension and deformation phenomena related to the deep drawing of a stainless steel sink (AISI 304 – 1.4301) were analyzed.

Deep Drawing Simulation: How it works

The deep drawing process is full of snares which traditional sheet metal forming does not have. DEFORM deep drawing simulation software is capable of virtually sampling and providing all of the indications to set a compliant and optimal work cycle.

DEFORM predicts bending, forming, springback and status variables in 3D progressive die forming simulations. The software supports a wide range of materials such as steel, aluminum, high-performance alloys and many more. It can also support the stress analysis of single and coupled mould, assess the influence of the material to be processed, the design parameters of the die or other process on the duration of the tool. The Forming Limit Diagrams (FLD) are supported to predict errors, while the Forming Limit Curve (FLC) acts as damage criterion.

BLANK

DEFORM software is capable of quickly performing the flat development of drawn sheet metal pieces and to compute stretching of the material in the different zones of the model. DEFORM supplies a thorough analysis on the behaviour of the material during the forming process, in addition to providing the calculation of the flat development of a drawn sheet metal part. DEFORM software quickly computes the flat development of the component to be analysed, highlighting possible implementation problems, determines material costs and improves the design and production process.

DEFORM is a tool dedicated to production and is therefore simple to use. The technical operator, the quality department and the technical department will use simulation daily to address problems with the workpiece. DEFORM can also be used in parallel by the Research & Development department for new products.

DEFORM software is designed to work on desktop PC or workstation. The Americans, manufacturers of DEFORM, came up with a complete, simple and fast software.

What customers say about DEFORM:

DEFORM deep drawing simulation software is American and has been optimised to be reliable, quick and easy.

EXCELLENT AGREEMENT OF “SOFTWARE RESULTS” WITH “REALITY” DEFORM is the most widely used cold forming simulation software in the world
SAMPLING IMMEDIATELY POSITIVEThe simulation makes it possible to identify defects obtained during forming, to understand their causes and therefore to undertake the right corrective actions
STARTING TIMES REDUCED TO A MINIMUM The press setting was already tested in simulation. The real sampling will dispose of the machine setup card already defined.
CERTAIN RAW MATERIAL PROCUREMENTThe DEFORM deforming simulation makes it possible to assess different extruded item diameters and therefore to immediately identify the diameter for each code
REQUIRED PRESS DEFINITION DEFORM indicates the required tonnage for each workstation and therefore indicates which machine is necessary for the process. Planning of samplings and production
LONGER MOULD DURATION Tool wear known and reduced thanks to modified mould mechanics. Mould damage phenomena eliminated because expected and therefore taken care of in simulation

For the purchase, hire or a DEMO of the software or if you want to take advantage of a simulation service specially-made by our technical department, write or call us at +39 030 3365383

References

Mori 2A: Deep drawing simulation with Deform software

28/02/2022

DEFORM

Mori 2A in collaboration with ECOTRE VALENTE carried out a deep drawing simulation of a sink. This analysis allows you to thoroughly examine all the phenomena that come into action during the drawing process, virtually sample and have all the information for setting up a compliant and optimal work cycle.
Thanks to the deep drawing tests carried out in DEFORM, Mori 2A can produce its sinks on the computer and know their performance and quality: required tons, shape, defects, wrinkles, cracks and elastic return.
Article in Italian

DEFORM: A software to combat expensive energy

22/02/2022

DEFORM

Ecotre Valente from Brescia proposes DEFORM to optimize costs through process simulations
Not only reductions in shiftwork and production in the lower cost ranges, energy savings can also come from a simple one software.
A popular saying goes that "necessity sharpens the wits", meaning that when you are in critical conditions it is a process of nature find new solutions to problems, and in this case to costs.
Precisely in the face of the expensive energy Ecotre Valente, it has decided to offer its customers a new weapon represented by the software DEFORM for the simulation of energy consumption in furnaces...
Article in Talian

NICRO: Radiant tube forming with DEFORM

29/12/2021

DEFORM

This study illustrated how DEFORM-3D predicted the influence of process parameters and geometric features on final product quality. The redevelopment project achieved the following objectives that led to reduced production costs.
• Cracking was eliminated and wrinkles were avoided in the final product.
• The robust design allowed for less stringent material requirements on the Alloy 601 sheet stock.
• Use of standard sheet stock increased flexibility in production scheduling and reduced costs, since the standard material was often on hand.
• The number of stamping operations was reduced from three to two, which shortened the production cycle time.
• Continuous processing eliminated the need for in-process inventory.
• Machine tooling and setup time were reduced.
• Overall delivery time was improved.

Eliminate scrap and defects with simulation

29/12/2021

DEFORM

The webinar dedicated to the novelties in the simulation of hot and cold forming, coining, drawing, shearing, rolling, forging, drawing, extrusion, welding with the new software DEFORM 2021 and organized by the Brescia-based company will be held on Thursday 1 July 2021.
Article in Italian

3D numerical simulation of sheet metal forming processes using solid element

03/12/2021

DEFORM

This paper addresses two issues in the 3-D numerical simulation of sheet metal forming processes. One is the implementation of an effective solid element on very thin metal sheet under the bending and drawing operations. The other is the use of parallel computational scheme to reduce the simulation time. Possible volumetric and shear locking phenomena for the thin structure with solid element are avoided by adopting the assumed strain concept.

Radiant tube forming simulation – Software DEFORM

03/12/2021

DEFORM

The case study was supplied by Nicro SpA of Vailate, Italy. It was performed in partnership with the University of Brescia and ECOTRE Valente Srl of Brescia, Italy.
ECOTRE is the exclusive distributor of the DEFORM system in Italy.
SFTC and ECOTRE would like to thank Mr. Marena Gianni for sharing this DEFORM experience.

The materials and the design of the die in a critical manufacturing step of an automotive shock absorber cap

03/12/2021

DEFORM

The industrial drawing of automotive shock absorber endcaps caused wear and radial brittle fractures of the tool steel dies. A finite element method (FEM) simulation of the process showed that this was caused by high contact and hoop stresses on the die. Such difficulties are usually solved by expensive changes in the die material, but a change in the punch design was proposed as a simpler and cheaper solution. The new punch geometries were employed in a FEM simulation of the drawing, indicating much lower contact and hoop stresses. The implementation of the solution eliminated the wear and brittle fracture problems.

Virtual press for die testing: product quality and equipment life – Software DEFORM

03/12/2021

DEFORM

1. The DEFORM software of simulation metal sheet forming, deep drawing, progressive forming, blanking and heat treatment showed the problems on the part. Excellent alignment of “Simulation Software Results” with “Reality”
2. The simulation allows to identify the defects obtained during forming and shearing, to understand the causes and then to take the right corrective actions. Positive sampling at the first shot, if simulated
3. Reliable raw material supply
4. Start-up times reduced to a minimum: coils, strips, sheets already defined
5. Machine definition required: sampling and production planning
6. Increased die life thanks to positive samples that do not require subsequent modifications and repairs, even with any welding. Wear, elastic deformations of the die, cracks identified by DEFORM
7. Estimate Reliability Verification
8. Shorter cycle time
Article in Italian

Demand for the “virtual factory” rises

02/12/2021

DEFORM

Ecotre Valente from Brescia distributes simulation software. Growing more than 20% annually in the last 5 years
It is a matter of time. The simulation software for casting, forging, rolling, heat treatment and machining allow to expand or compress it: ingots of tons that take days, to give just one example, can be reduced and evaluated in a few minutes; conversely, steps of a few thousandths can be analyzed in hundreds of seconds. But the time factor today is also the key to the diffusion process of these virtualization programs of the production cycle. "It's only a matter of time: even in the world of steel, the tools that allow the virtual reality of production processes will be widespread."
Article in Italian

Ecotre-Techne: simulation and tomography

16/06/2018

DEFORM

Create virtual twins. Also virtualization did leaps and bounds, permitting to recreate with a precision that touches 100% an object directly on the monitor of a pc.
Article in Italian