Process design and blank modification in the multistage rectangular deep drawing of an extreme aspect ratio

We have carried out finite element analysis to achieve the multistage deep drawing of a rectangular configuration with an extreme aspect ratio, focusing on the process design. Analysis of a rectangular deep drawing process with an extreme aspect ratio is very difficult in regard to the design process parameters, including the intermediate die profile. To solve these difficulties, a numerical approach using a finite element method was performed. A series of multistage rectangular deep drawing experiments were conducted, and the deformed configuration was compared to the results of the finite element analysis. Additionally, to minimize the amount of removed material after the trimming process, a finite element simulation was applied to a blank modification. The analysis incorporated brick elements in a rigid-plastic finite element method with an explicit time integration scheme using LS-DYNA3D software.