Numerical and experimental study of surface deflection in rectangular embossing

Recently, numerical predictions of surface deflection by the panel geometry after springback analysis have been carried out by curvature analysis and stoning simulation. This study focused on the accuracy of surface deflection quantification by using these methods. In curvature analysis, the measure of surface deflection was defined as the maximum variation of curvature difference between the panel and the tool to cope with surfaces that have high curvature. In stoning simulation, for the unscratched region, maximum depth and length were calculated. A novel measure for stoning was suggested to quantify the surface deflection by assuming the section shape of surface deflection. As an example, a shallow rectangular drawing with inner rectangular embossing was considered. In curvature analysis, the maximum variation of curvature was in very good agreement with the one from the experiment. In stoning simulation, even though the maximum depth and length of surface deflection by simulation was somewhat larger than the ones from the experiment, both the simulation and experiment show good correspondence in terms of the proposed measure. Both methods can be effectively used for the quantification of surface deflection with the aid of an appropriate measure.