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The technology of multistage deep drawing has been widely applied in the metal forming industry, in order to reduce both the manufacturing cost and time. A battery can used for mobile phone production is a well-known example of multistage deep drawing. It is very difficult to manufacture a battery can, however, because of its large thickness to height aspect ratio. Furthermore, the production of the final parts may result in assembly failure due to springback after multistage deep drawing. In industry, empirical methods such as over bending, corner setting and ironing have been used to reduce springback. In this study, a bottoming approach using the finite element method is proposed as a practical and scientific method of reducing springback. Bottoming induces compression stress in the deformed blank at the final stroke of the punch and, thus, has the effect of reducing springback. Different cases of the bottoming process are studied using the finite element program, DYNAFORM, to determine the optimal die design. The results of the springback simulation after bottoming were found to be in good agreement with the experimental results. In conclusion, the proposed bottoming method is expected to be widely used as a practical method of reducing springback in industry.

Springback Minimization using Bottoming in Al Can Deep Drawing Process