Effect of Gradual Punch Speed Variation on Thinning and Springback in Deep Drawing Using Finite Element Analysis

Abstract

Deep drawing is one of the primary sheet metal forming processes used to manufacture three-dimensional components for various industries such as automotive and household appliances. Among the major challenges associated with this process are maintaining uniform thickness distribution and reducing springback, due to their direct effect on the quality of the final product. This study aims to analyze the effect of gradually varying punch speed during the deep drawing process on thickness distribution and springback using ABAQUS software based on the finite element method (FEM). A three-dimensional numerical model of the process was developed by defining the mechanical properties of the material, the friction coefficient, and the die geometry. Different gradually varying punch speeds were applied and compared with the constant punch speed condition. The results showed that the gradual speed variation improved thickness distribution by approximately 5% compared with the constant speed case. However, the high constant punch speed achieved the lowest springback value, reducing it by 9.5% compared with the gradual speed reduction condition. Furthermore, Speed control contributed to reducing stress concentration in critical regions, particularly at corner areas. The findings highlight the importance of numerical simulation as an effective tool for optimizing process parameters, reducing manufacturing cost, and improving the quality of final industrial products.