Investigating Thinning and Wrinkling in Deep Drawing Processes: A Comparative Analysis of Two Punch Designs on 2.5 mm Aluminum Sheets

In order to minimize trial-and-error costs and avoid any faults throughout the production process, sheet metal forming is commonly used in the automotive industry to fabricate body pieces. This study examines how several punch models affect thinning and wrinkling during the deep drawing of aluminum 1050, a 2.50 mm thick material, under 150 KN of pressure. The Forming Limit Diagram (FLD) was used in the simulations to study material deformation and determine safe and essential places on the blank. According to the findings, die pressure-induced material stretching caused the material to significantly rise in major-minor strain, major-minor stress, thinning, and wrinkling by the fifth step. Additionally, for punch 1 material, the safe area grew from 9.20% to 49.36%; punch 2 increased from 9.08% to 46.85%. The non-linear FLD graph analysis verified that both materials stayed in the safe zone the entire time. These results demonstrate how well deep drawing simulations work to improve punch design and aluminum component performance in the automobile industry.