Production of a headlight replica

The thesis deals with the design of a headlight reflector production. The sheet thickness of DC04 material is 0,6 mm. Various technologies were evaluated, and hydromechanical deep drawing was chosen due to the complexity of the component shape. The semi-finished product will be a circular sheet with a radius of 117 mm, which will be cut out from metal sheets measuring 2500 x 1500 mm. The component will be manufactured in a single drawing operation. The total forming force is calculated 171 kN. Subsequently, a simulation of the drawing process was conducted, confirming the manufacturability of the part. The maximum forming force reached 226,6 kN. The ZH 30 press was chosen, and the tool design was proposed