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Root Cause Analysis of Deep Drawing Processes with Superimposed Low-Frequency Vibrations on Servo-Screw Presses - A Practical Research on Predictability in Simulation

In the area of sheet metal forming, modelling and simulation of deep drawing processes with finite-element analysis are an essential method for an accurate process design and the production engineering of complex parts. The continuous evaluation and qualification of simulation strategies improve the predictability and help to understand complex forming processes. In order to fulfil the constantly growing requirements on product quality and part variety, dimensional accuracy as well as energy and cost efficiency, it is necessary to achieve reasonable forecasting results and optimal parameters. However, the development of enhanced deep drawing techniques supported by vibrations is in general just beginning. Currently, prediction of process parameters as well as the knowledge about effects and coherences of highly dynamic processes with flexible kinematics are insufficient. In this paper, an approach for improvements in simulation of a new technology for deep drawing on servo-screw presses called cushion-ram pulsation is presented. Numerical and experimental model tests in special constructed set-ups have to be performed to determine particular forces. Sensitivity based methods help to identify significant process parameters of complex forming processes with superimposed vibrations. The evaluation of these parameters allows the development of specific meta-models which approximate the behavior in the simulation.