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Optimization of ironing processes by means of DOE and FEA

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Abstract

The range of possible applications of ironing processes reaches from the production of cylindrical pressure tanks, shock absorber pipes, battery and beverage cans to the production of flacons for the cosmetics industry. One goal of the finite element analyses of ironing processes is to gain knowledge about process limits regarding maximized forming capacity and optimized surface quality. The ironing process is characterized by parameters like friction, geometry of the ironing ring and anisotropic material behavior. Due to the high complexity of this process, it is complicated to detect these effects on the basis of experimental investigations only. Therefore, one of the aims of this study is to identify relevant process parameters by means of systematic numerical analyses. The design of experiments was utilized to create a model of the ironing process. By means of this model it was possible to reduce the punch load and to minimize the tensile stresses in the first stage of the analyzed ironing process.

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Acknowledgments

The work presented was accomplished in the context of the project Do 190-145-1. The authors thank the Deutsche Forschungsgemeinschaft (DFG) for the financial support of the project.

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Authors and Affiliations

  1. Institute of Metal Forming and Metal-Forming Machines, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Bernd-Arno Behrens

  2. Nagel Profiliertechnik GmbH, Uferstraße 22, 72229, Rohrdorf, Germany

    Olaf Pösse

  3. AutoForm Engineering Deutschland GmbH, Emil-Figge-Str. 76-80, 44227, Dortmund, Germany

    Martin Milch

  4. Institute of Metal Forming and Metal-Forming Machines, CA-Technologies, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Gabriele Helms

Authors
  1. Bernd-Arno Behrens
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  2. Olaf Pösse
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  3. Martin Milch
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  4. Gabriele Helms
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Correspondence to Gabriele Helms.

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Behrens, BA., Pösse, O., Milch, M. et al. Optimization of ironing processes by means of DOE and FEA. Prod. Eng. Res. Devel. 1, 3–8 (2007). https://doi.org/10.1007/s11740-007-0023-y

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  • DOI: https://doi.org/10.1007/s11740-007-0023-y

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