Development of the Internal Combustion Engine Oil Pan in Deep Drawing Process: FE Simulation and Experimental Validation

In this study, the forming process of JAC270F sheet metal with a thickness of 1.2 mm was investigated to produce a complete "INTERNAL COMBUSTION ENGINE OIL PAN." A novel two-step forming method, termed the “Two-Steps Deep Drawing Process,” was proposed, along with the application of “Finite Element Analysis (FEA)” using the AutoForm software to achieve highly realistic forming simulations. Material models, including the Barlat yield function, Swift hardening law, and forming limit diagrams from the Keeler equation, were employed. Additionally, key parameters influencing the successful formation of the INTERNAL COMBUSTION ENGINE OIL PAN without defects were examined. The use of a blank holder force of 7.5 tons, a die radius of 9.6 mm, and a reduction in the coefficient of friction to 0.11 effectively eliminated cracks and wrinkles in the part. The simulation accuracy for part thinning and springback showed deviations of 5.45% and 2.01%, respectively, when compared to the experimental results. In conclusion, the finite element method enables accurate simulation and resolution of issues encountered in actual workpieces, reducing time and material waste from the trial-and-error process in the physical production setup precisely.