Numerical Investigation and Optimization of Blank-Holder and Magnetorheological Actuators Configurations for Deep Drawing Objectives

Abstract:

This study investigates the structural response of blank-holders (BHs) equipped with spatially distributed magnetorheological (MR) actuators for adaptive deep drawing. While MR actuators provide fast, independent, and high-resolution force modulation, their effectiveness depends critically on the BH’s ability to transmit spatially differentiated loads without excessive diffusion or unrealistic stress localization. The relationships between BH stiffness, actuator spacing, and pressure localization at the sheet interface remain only partially understood, limiting the implementation of distributed blank-holding strategies. To address this gap, a comprehensive finite element (FE) framework is developed, combining a full closed-cup deep-drawing model with a complementary simplified configuration that isolates local deformation mechanisms under single-actuator loading. Parametric analyses examine the influence of BH thickness, local actuator force, and actuator spacing on stress distribution, localization radius, and overlap between adjacent load paths. Results show that BH thickness is the dominant factor governing spatial resolution: thinner BHs enable sharp pressure localization, whereas thicker ones diffuse local loads and suppress stress peaks. The spacing between actuators must therefore be selected as a function of BH stiffness to avoid stress-free regions while preserving distinct pressure footprints. For the reference industrial configuration (60 mm BH thickness), an actuator spacing of approximately 150 mm achieves the optimal compromise between localization capability and continuous sheet support. The proposed framework establishes quantitative design criteria for BH geometries compatible with MR-based adaptive forming and supports the development of next-generation blank-holding systems offering enhanced process stability, reduced scrap, and improved material-flow control.

• Periodical: Solid State Phenomena (Volume 389)
• Pages: 83-94
• DOI: https://doi.org/10.4028/p-g9Pcig
• Online since: April 2026
• Authors: Mattia Dal Maso*, Enrico Simonetto, Andrea Ghiotti, Stefania Bruschi, Stefano Filippi, Lukas Hauser, Mathias Liewald
• Keywords: Blank-Holder, Deep Drawing, Ferrofluid, Magnetorheologic Actuator, Numerical Simulation, Pressure Distribution, Sheet Metal Forming

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