Optimization of ironing processes by means of DOE and FEA

The range of possible applications of ironing processes reaches from the production of cylindrical pressure tanks, shock absorber pipes, battery and beverage cans to the production of flacons for the cosmetics industry. One goal of the finite element analyses of ironing processes is to gain knowledge about process limits regarding maximized forming capacity and optimized surface quality. The ironing process is characterized by parameters like friction, geometry of the ironing ring and anisotropic material behavior. Due to the high complexity of this process, it is complicated to detect these effects on the basis of experimental investigations only. Therefore, one of the aims of this study is to identify relevant process parameters by means of systematic numerical analyses. The design of experiments was utilized to create a model of the ironing process. By means of this model it was possible to reduce the punch load and to minimize the tensile stresses in the first stage of the analyzed ironing process.