Ironing force modeling analysis on aluminum cup using CATIA V5

Wall-ironing is a metal forming process to reduce the wall thickness and increase the cup length. Ironing is a bulk forming process where the deformation force (tensile force) must be absorbed by the cup wall which is deformed. In the ironing process, the thickness reduction ratio or TRR is an important factor. If TRR is low to achieve the desired thickness, the process should be carried out several times. The greater the TRR, the more increased tensile force resulting in a larger stress. If the stress in the formed cup wall exceeds the tensile strength of the cup material, the base is torn off. This stress must be between the yield and the ultimate stress of the material. The die angle also affects the ironing force. This research is using CATIA software in order to get the die angle, TRR, and ironing force relationship. In this study, the products used are deep-drawn aluminum cup 37 mm of outer-diameter, 32 mm inner-diameter, 20 mm height, and 2.5 mm wall thickness. Outer wall thickness is reduced with varying TRR of 30%, 20% and 10%. Reducing process is done through ironing force on punch (punch force) inside the cup, whereas outer wall of cup is reduced through die ring with various die angle 5°, 10°, 15°, 20°, 25°, and 30°. By using CATIA modeling and stress analysis simulation, we can obtain stress (Von Misses stress) that occur on cup wall. The results of varying ironing force modeling simulation with 30%, 20%, 10% of TRR and 5°, 10°, 15°, 20°, 25°, 30°of die angle, can be obtained the occuring Von Misses stress. Based on this stress, the most optimal condition can be selected i.e. 30°of die angle for 30% of TRR, 15°of die angle for 20% of TRR, and 10°of die angle for 10% of TRR. Furthermore, this method can be used to analyze the research related to the press tool design on metal forming, especially the ironing with different methods.