P 931 - Numerical optimisation of the deep drawing process when using drawing beads by developing a well-founded extended replacement model

These are usually not sufficiently taken into account by the numerical design of the process, as substitute models are often used here. These only consider the restraining and hold-down forces and not the actual material behaviour. These conditions and their interactions should be included in the considerations. The aim is to optimise the substitute model and the input variables for a simulation. Several experimental investigations have been carried out to characterise the material properties of the existing sheet materials DX56D+Z (1.0963) and HCT780X (1.0943). Numerical simulations of the characterisation tests supplement the experiments for a realistic representation of the material behaviour in the process. The force and friction ratios are to be recorded with the aid of a corresponding conversion of a friction test bench with modified tools and used to optimise the input variables for FEM simulation software. The occurring tensile, compressive and bending stresses as well as their superpositions from the real deep-drawing process are to be reproduced experimentally on suitable test facilities and the influences on the material behaviour verified using FEM simulations. The results sought in the proposed research project will contribute to the further development of products to a clearly defined extent. In addition to products that are made available to users by software development companies, the manufacture of tools and machines for forming technology and the components produced using forming processes, especially the deep drawing of sheet metal materials, should be mentioned here. As processes and procedures can be designed with better quality thanks to optimised input variables, it is also possible to design, construct and manufacture machines and tools more precisely. This results in a reduction in labour, personnel, material and financial resources for small and medium-sized companies. Conversely, improved products, e.g. simulation software, forming tools and forming machines, offer the opportunity to further develop the procedures for the numerical and constructive design of a forming process. design of a forming process can be further developed and optimised.