Work hardening models and the numerical simulation of the. Because a part wrinkled during the deep drawing process will not be accepted and most likely become as scrap. Deep drawing provides a great application potential for the manufacturing of parts with complex shapes, even in very small dimensions. Moreover, since most of the sheet surface in the area between the punch tip and blank holder is free, wrinkles appear on the wall of the drawing part. The blank drawability has been related both theoretically and experimentally with the initial diameter of the blank and deep draw ing parameters. Numerical analysis on the effects of the friction coefficient on the deep drawing of a rail p. In deep drawing process the main objectives are to obtain defect less or minimum defects in product.
Analysis and experiment this paper reports on the initial stages of a combined experimental and finite element analysis fea. Effects of various parameters in deep drawing process over. In this paper, a finite element fe model is developed for the 3d numerical simulation of deep drawing process parametric analysis. Figure 5 shows the typical shape characteristics and thickness variations of a. Deep drawing is a vital procedure utilized for making cups from sheet metal in huge quantities.
The deep drawing process, as one of the most applicable sheet metal forming process, is widely used in many industries. The initial solution is optimized by means of an algorithm that minimizes the total time of the global process, based on relationship between lengths, diameters, and velocities of. Sheet metal forming is a complex process involving geometric, material and. In this research, geometric parameters were given in dimensionless form by the buckingham pi dimensional analysis method, and a series of dimensionless groups were found for deep drawing of the round cup. The effects of the parameters on the limit drawing ratio were numerically examined and compared. It is thus a shape transformation process with material retention. Optimization of deep drawing process for circular cup forming.
This paper reports on the initial stages of a combined experimental and finite element analysis fea of a deep drawing process. The process was simulated by finite element analysis using a commercial implicit fem package abaqusstandard to establish the base for our following analysis. The design of experiments doe was employed to make various reasonable combinations of process parameter levels, namely punch velocity, blank holder force, friction coefficient and initial forming temperature of blank. A deep drawing rig was designed and built for this purpose. Prediction of the forming results, determination of the thickness distribution and the thinning of the sheet metal blank will decrease the production cost through saving material and production time.
For deep drawing without a blankholder thickness ratio should be at least 3%. The factors affect the deep drawing process may be. In this work, a series of tests were conducted to investigate the deep drawing of aa6111 aluminum alloy at elevated temperatures. Theoretical and experimental analysis of deep drawing cylindrical. Anshul bindal econtent for aktu manufacturing technology1 duration. The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. The process of learning as shown by the mirrordrawing. A copy of the deep drawing analysis is made and placed on a new tab. Conventional deep drawing conventional deep drawing can be achieved without a blank holder as indicated in figure 1, or with a blank holder as shown in figure 2 malinin 1975. We are a leading manufacturer specialized in sheet metal fabrication mainly stamping and welding parts since 1997, we are located in laizhou, shandong, china, 150 kilometres away from qingdao port. Pdf experimental and numerical analysis of the deep.
Under certain conditions, this sliding will cause friction between the tools and the material. To reduce various defects in deep drawing process it is necessary to control some parameters of deep drawing process. The strength difference and the initial anisotropy induce uneven. Pdf design and analysis of deep drawing process on. The deep drawing process involves a great deal of sliding of the sheet material along the tools. The blankholder force was the initial force applied when the punch touched the material. Blankingblanking is the process ofcutting the initial sheet coil stockinto round or shaped flatsrequired for deep drawing. Experimental analysis can be useful in analyzing the process to determine the process parameters that produce a defect free. Finite element simulation of single stage deep drawing. The vbhf experiment is under preparation to validate this simulation. Pdf analysis of deep drawing process for hemispherical products.
Deep drawing is affected by many factors such as material properties, tool geometry, lubrication etc. Prediction of wrinkling is a very important process for a deepdrawing operation. A deep drawing rig was designed and built for this. Analysis of punch velocity dependent process window in. Knightly university of massachusetts amherst follow this and additional works at. The application of the finite element method to the numerical simulation of the deepdrawing process has evolved in a.
There are mainly two methods of deep drawing analysis. The objective of this research is to determine the most important factors influencing a drawing process, utilizing the help of a design of experiments and statistical analysis. In this paper, a finite element fe model is developed for the 3d numerical simulation of deep drawing process parametric analysis by using abaqusexplicit fea program with the. The process is considered deep drawing when the depth of the drawn part exceeds its diameter. However, this process is carried out usually under laboratory conditions with a relatively low punch velocity, for example 1 mms. The process requires sheet metal with a high thickness ratio, to avoid wrinkling. Experimental analysis can be useful in analyzing the process to determine the process parameters that produce a defect free product, and the analyticalnumerical modeling can be used to model and analyze the process through all stages of deformation. We also believe that learning about design and analysis of experiments is best achieved by the planning, running, and analyzing of a simple experiment. Concerning the so called size effects micro deep drawing is widely investigated. Deep drawing process analysis and experiment free download as pdf file.
Finite element analysis of deep drawing and springback failure criteria two types of failures were followed through the modeling. Detailed experimental and numerical analysis of a cylindrical. The objective of this research is to determine the most important factors influencing. It is concluded the similarity between the numerical and experimental results and these is a started point in the creation of a database for tribological behaviour of materials in deep drawing processes. Deep drawing deep drawing deep drawing is defined as a. Optimization of the deep drawing process can reduce the amount of product defects, production cost and can improve the quality of prod ucts. Deep drawing process is a sheet metal forming process where a. Ruptures in deep drawing, bioresources 112, 46884704. Analysis of an axisymmetric deep drawn part forming using. Pdf deep drawing process is a significant metal forming process used in the sheet metal forming operations. The process of learning as shown by the mirrordrawing experiment agnes e.
Deep drawing process analysis and experiment experiment. With these considerations in mind, we have included throughout the book the details of the planning stage of several experiments that were run in the course of teaching our. Analysis and experiment this paper reports on the initial stages of a combined experimental and finite element analysis. Deep drawing, springback, finite element analysis, aa5754o. Investigation of hydrodynamic deep drawing for conicalcylindrical cups because of lowcontact area of the sheet with punch tip in the initial stages of forming, bursting occurs on the sheet. It was observed that the punch force required for deepdrawing increases with anisotropy in the blank sheets. The objective of this study is to determine the factors influencing a drawing process. Deepdrawing parameters, bioresources 122, 35303545. Colgan and monaghan, performed an experimental and numerical analysis of the process and therefore a comparison between the present work against the values which have been recorded for the blank thickness of the deep drawn cup may be used to validate the model. To do the deep drawing experiment of brass or any metallic specimen with the help. This work reports on the initial stages of finite element analysis fea of a deep drawing process.
Deep drawing dd is one of the sheet metal forming processes widely used in. Rightclick the original analysis tab and select copy rightclick again and select paste. Click the select process and material bu on to open the selec on dialog. Presented contribution deals with force parameters research drawing and blankholding in deepdrawing process of flat bottomed cylindrical cup. Deep drawing for a circular cup a initial stage and. The major conclusions drawn from this study are as fallows. Influence of process parameters on deep drawing of aa6111.
Theoretical and experimental analysis of deep drawing. Analysis of original drawing process the existing forming process consists of 10 steps, that is, 7step, 2step and 1step drawing to form zone i, zone ii and zone iii, respectively. It has been accepted for inclusion in masters theses 1911. Various results are illustrated in the details, compared and discussed. Because of these factors, some failures may occur during the process. Investigation of a new methodology for the prediction of. The strains in the radial and circumferential directions have been measured. Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a. Investigation of hydrodynamic deep drawing for conical. Discrete element and finite element coupling simulation and experiment of hot granule medium pressure forming. Circular cup drawing is the most basic process among the deep drawing processes. Circumferential tensile strain radial tensile strain ironing. Design and operation of experimental deep drawing rig. Deep drawing process analysis and experiment experiment nature.
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