A new process optimization of deep drawing part for sheet metal forming in automotive industry - Research Article

Oct 29, 2026

Research investigates deep drawing of sheet metal for automotive body side inner panels with depth over 110 mm, targeting reduction of tearing, thinning, and crack occurrence while lowering stamping line stoppage time and production scrap. Drawing die operation complexity is addressed by decreasing die operation numbers to reduce project budget consumption. Problem-solving techniques identify root causes, then force, blank cutting, and blank location effects are examined alongside process optimization parameters. Conducted at Ford Otosan, formability improves and scrap and stoppage time decrease over 90%.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages9

Reading Time23 min

AccessFree to download

Aim

Design & Methodology

Originality

Findings

Conclusion

Declaration of Ethical Standards

ABSTRACT

Keywords

1. INTRODUCTION

POLİTEKNİK DERGİSİ JOURNAL of POLYTECHNIC ISSN: 1302-0900 (PRINT), ISSN: 2147-9429 (ONLINE) URL: [http://dergipark.org.tr/politeknik](http://dergipark.org.tr/politeknik) A new process optimization of deep drawing part for sheet metal forming in automotive industry Yazar(lar) (Author(s)): Mehmet Burak MISIRLI 1 , Aysun Ayday2 ORCID 1 : 0000-0001-7993-2932 ORCID2 : 0000-0003-3719-7006 Bu makaleye şu şekilde atıfta bulunabilirsiniz(To cite to this article) : Mısırlı M. B., Ayday A.,“A new process optimization of deep drawing part for sheet metal forming in automotive industry”, Politeknik Dergisi, 25(2): 879-885,(2022) . Erişim linki (To link to this article): [http://dergipark.org.tr/politeknik/archive](http://dergipark.org.tr/politeknik/archive) [DOI:](DOI: 10.2339/politeknik.911780)[ 10.2339/politeknik.911780](DOI: 10.2339/politeknik.911780) A New Process Optimization of Deep Drawing Part for Sheet Metal Forming in Automotive Industry Highlights ❖ Stamping ❖ Deep Drawing ❖ Drawing Die ❖ Sheet Metal Forming ❖ Stamping die process optmization Graphical Abstract The stamping line stoppage time related with tearing problems were reduced to the lowest level, at the end of the study. Figure. Line stoppage trend Aim It is aimed to eliminate the tearing problem that occurs in the sheet metal forming process, which is apart of automotive production. Design & Methodology Problem solving techniques were applied to determine the root causes of the problems and research was conducted for each root cause. Originality In order to eliminate a problem in mass automotive production, experiments on the geometry of the blank sheet metal were made in the simulation environment and the most suitable one was tried under the conditions of mass production. Findings A relationship/ratio was determined between the drawbead force and the blank sheet metal's cut-out geometries. Conclusion According to the found ratio, a new type of blank sheet metal cut-out geometry was created and the problems were minimized by testing it under mass production conditions. Declaration of Ethical Standards The author(s) of this article declare that the materials and methods used in this study do not require ethical committee permission and/or legal-special permission. A New Process Optimization of Deep Drawing Part for Sheet Metal Forming in Automotive Industry Araştırma Makalesi / Research Article Mehmet Burak MISIRLI, Aysun AYDAY* Faculty of Engineering, Metallurgical and Materials Engineering Department, Sakarya University, Turkey (Geliş/Received : 09.04.2021 ; Kabul/Accepted : 10.09.2021 ; Erken Görünüm/Early View : 30.09.2021) ABSTRACT Drawing die complexity is higher than conventional stamping operations, nowadays. It needs to decrease stamping die operation numbers for a part to reduce project budget consumption. Therefore, frequency of tearing, thinning, crack occurrence increase while this amendment. Force, blank cutting, blank location on the drawing die and process optimization were investigated to decrease tearing, thinning and crack occurrence in Transit bodyside inner panels which have over 110 mm. deep drawing process. Formability was improved at the end of this study. Thus production scrap, stoppage time of stamping line were decreased over 90% . This study was conducted at Ford Otosan. Keywords: Stamping, deep drawing, sheet metal forming, drawing die, stamping dies process optimization, press. 1. INTRODUCTION Production cost has increased because of new mobility systems such as self driving, electirification or driving assistance systems in the last 20 years in automotive industry [1-3] . So, new method and optimization systems are investigated by engineers and technicians to decrease budget of projects without reducing quality of final parts on main frame of cars [1]. Raw materials are the first key point of the production budget in automotive industry [3,4]. In these

FAQs

What problem does the study aim to eliminate in automotive sheet metal forming?

It aims to eliminate tearing occurring during the sheet metal forming process used in automotive production.

What variables are investigated to reduce tearing, thinning, and cracks?

The study investigates force, blank cutting, blank location on the drawing die, and process optimization parameters such as drawbead force and other forming forces.

How is the improved blank geometry validated and what result is reported?

A new blank sheet metal cut-out geometry is created according to a determined drawbead force-to-geometry ratio and tested under mass production conditions, reducing production scrap and stamping line stoppage time by over 90%.

Oct 29, 2026

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