FEM simulation of surface smoothing in the ironing process

The purpose of this paper is to simulate surface smoothing in the ironing process by elasto-plastic FEM. The simulated results show that surface smoothing is largely developed during a very short contact length from the entrance of the contact zone where the material is in the elastic state and can be remarkably promoted by the plastic deformation in the surface layer. With increase in the reduction in thickness, in the die angle and in the friction coefficient on the punch side, the surface smoothing of the workpiece can be accompanied at the shorter contact position from the entrance of the contact zone. The simulated results are in good agreement with experimental results. (C) 2001 Elsevier Science B.V. All rights reserved.