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

doi:10.21741/9781644903599-121

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

Grundfos DK AS

Research output: Chapter in Book/Report/Conference proceeding › Article in proceedings › Research › peer-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 language	English
Title of host publication	Materials Research Proceedings
Publisher	Materials Research Forum LLC
Publication date	2025
Pages	1114-1123
DOIs	https://doi.org/10.21741/9781644903599-121
Publication status	Published - 2025
Event	Metal Forming: The 28th International ESAFORM Conference on Material Forming - Paestum, Italy Duration: 7 May 2025 → 9 May 2025

Conference

Conference	Metal Forming
Country/Territory	Italy
City	Paestum
Period	07/05/2025 → 09/05/2025

Keywords

Ironing
Flexible Forming Tools
Friction
Numerical Simulation

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title = "Experimental and numerical analysis of an improved adjustable ironing punch design",

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.",

keywords = "Ironing, Flexible Forming Tools, Friction, Numerical Simulation",

author = "Kaarel Siimut and Madsen, {Kasper Mygind} and Ermanno Ceron and Brian M{\o}ller and Giuliano Bissacco and Nielsen, {Chris Valentin}",

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language = "English",

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AU - Siimut, Kaarel

AU - Madsen, Kasper Mygind

AU - Ceron, Ermanno

AU - Møller, Brian

AU - Bissacco, Giuliano

AU - Nielsen, Chris Valentin

PY - 2025

Y1 - 2025

N2 - 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.

AB - 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.

KW - Ironing

KW - Flexible Forming Tools

KW - Friction

KW - Numerical Simulation

U2 - 10.21741/9781644903599-121

DO - 10.21741/9781644903599-121

M3 - Article in proceedings

SP - 1114

EP - 1123

BT - Materials Research Proceedings

PB - Materials Research Forum LLC

T2 - Metal Forming

Y2 - 7 May 2025 through 9 May 2025

ER -

Experimental and numerical analysis of an improved adjustable ironing punch design

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