Finite Element Simulation of a Multistage Square Cup Drawing Process for Relatively Thin Sheet Metal through a Conical Die

A new manufacturing process has been developed that involves drawing circular sheets of thin metal through a conical die to create square cups. This technique produces deep square cups with a height-to-punch-side length ratio of approximately 2, as well as high dimensional accuracy and a nearly uniform height. The study investigated how various factors, including the sheet material properties and process geometric parameters, affect the limiting drawing ratio (LDR). The researchers used finite element analysis to determine the optimal die design for achieving a high LDR and found that the proposed technique is advantageous for producing long square cups with high dimensional accuracy.