Comparative evaluation of formability in cup drawing and V-bending using additively manufactured tools

Additive Manufacturing (AM) is rapidly transforming industrial processes by introducing advanced methods for designing, manufacturing, and prototyping key components across various industries. Its true potential is realized in integrated component repair via reverse engineering, significantly reducing rework, maintenance costs, and time. With growing demand, AM technology continues to evolve, incorporating intelligent printing systems and diverse applications in sectors like automotive, sheet metal forming, healthcare, aviation, and consumer goods. AM also aids in optimizing geometric and process parameters for tools such as dies, punches, and blank holders, enhancing economic batch production. This study focuses on the Finite Element Analysis (FEA) of two commercial operations: bending and deep drawing, using DC04 and AA6060 materials. The analysis identifies geometric precision, thinning, and formability. In steel, increasing the bottom radius from 3 mm to 20 mm results in an 11% difference in thinning, with a maximum of 0.67 mm. For aluminium, thinning varies minimally between 0.68 and 0.75 mm. Increased sheet thickness limits formability in both materials. FDM-printed tools were used for FEA simulation, followed by stress analysis of dies to assess design safety, small batch production, and dimensional conformity.