PVD coated dies in action: Exploring finite element analyses for sheet metal forming of high‐strength steel

Abstract This research proposes a complete analysis of the use of physical vapour deposition coated dies in the sheet metal forming process for high‐strength‐steel sheets. The goal of the proposed approach is to investigate how PVD coatings affect die performance and how that affects the formability and quality of the high‐strength‐steel‐sheets that are made. The finite element analyses are used to simulate and evaluate the mechanical behaviour and deformation characteristics during the forming process. Studies to enhance the forming characteristics of these materials, typically denoted by limiting draw ratio and maximum punch force are required. A reduction in punch force required and improved limiting draw ratio is observed that is attributed to the enhanced contact with friction‐conditions in the die‐sheet interfaces. The experimental results are compared with simulation results from DD3IMP, a code used for deep drawing simulations, and it is evident that the experimental outcomes are analysed well with the simulation results.