Improving parameters for achieving uniform cylindrical cup wall thickness in two-step deep drawing processes with SPCC sheet material

Deep drawing processes are essential in modern manufacturing for creating intricate components with deep hollows, particularly cylindrical forms. These processes are widely used in industries such as household appliances, automotive manufacturing, aerospace engineering, and fire safety equipment. This study focuses on the two-step deep drawing of cylindrical cups, utilizing both simulation and experimental methods. The primary goal is to determine optimal geometric and technological parameters for mold design and to address issues like wrinkling and tearing. Key parameters, including punch nose radius (Rpf), die nose radius (Rdf), punch-die clearance (Wf), and blank holder force (BHF), are systematically analyzed. Results show that proper parameters lead to a uniform wall thickness, with deviations reduced to 4.77%. Conversely, improper parameters result in a 12.03% deviation. Improved parameters in the second-step deep drawing yield cylindrical cups that closely match experimental outcomes, free from wrinkling or rim cracking. This research highlights the importance of selecting appropriate parameters to avoid defects.