Experimental and numerical analysis of an improved adjustable ironing punch design

Kaarel Siimut*, Kasper Mygind Madsen, Ermanno Ceron, Brian Møller, Giuliano Bissacco, Chris Valentin Nielsen*

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review

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Abstract

In-line adjustability of tools for high-volume forming processes could improve yield while reducing lubricant use. This work presents an improved design of an ironing punch with adjustable tool diameter and an experimental study of its performance. Experimental results are compared with numerical simulations conducted in LS-DYNA. Punch retraction force of the new design was 68-85% lower than that of a conventional punch, indicating a lower contact pressure and thus reduced tool wear. The wall thickness of the ironed cups was adjusted by about 25 µm.
Original languageEnglish
Title of host publicationMaterials Research Proceedings
PublisherMaterials Research Forum LLC
Publication date2025
Pages1114-1123
DOIs
Publication statusPublished - 2025
EventMetal Forming: The 28th International ESAFORM Conference on Material Forming - Paestum, Italy
Duration: 7 May 20259 May 2025

Conference

ConferenceMetal Forming
Country/TerritoryItaly
CityPaestum
Period07/05/202509/05/2025

Keywords

  • Ironing
  • Flexible Forming Tools
  • Friction
  • Numerical Simulation

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