Efficient net shape forming of high-strength sheet metal parts by Transversal Compression Drawing

Abstract In this contribution, a new forming method is presented for high-strength steel sheet metal materials called Transversal Compression Drawing (TCD). For TCD, the blankholder of the conventional deep drawing process is replaced by sliders introducing a vertical force along the blank edge. Compared to conventional deep drawing, compressive stresses are thereby superimposed in the flange area of the sheet metal material, reducing the springback of formed components and the forces required during the process. Proof of this is provided here on the basis of numerical investigations in which conventional deep drawing and TCD are compared using the example of an “S-Rail” component made from DP980. Results of these investigations reveal that with TCD a maximum reduction in springback by more than 5 mm is achieved, leading to an improvement in the component´s overall shape accuracy of more than 55%. Furthermore, frictional work is decreased by − 6.92 kJ/kg, resulting in an overall reduction of maximum forming forces by 67.4%. Besides, TCD enables a trim-free net shape forming of the final part contour in a single operation and an increased material utilization of 4.5% from coil to part. Not least, no sheet thinning occurs with TCD, whereas a maximum thinning of 12% is observed with the conventional deep drawing process.