Finite Element Analysis of Bulging Forming for Sheet Metal with Bottom Compression Drawing Method

Abstract

For the bulging forming of sheet metal industry, two of the major disadvantages are large punch load and short bulging height, generally referring to the traditional process. In this present work, a new processing technique had been introduced for bulging forming based on bottom compression drawing method. The finite element method (FEM) with DEFORM-2D was used to investigate the bulging process. Besides, the mechanism of dimple defect occurred in bulging process was analysed with numerical simulation. The results showed that the dimple defect divided into four stages in the bulging process, where revealed an inverted cone-shape at the bottom part of the centre workpiece. Moreover, the laboratory experiments were carried out to validate the results of numerical simulation, which showed a good agreement with the FEM simulation results.