The effects of the parameters on the limit drawing ratio were numerically examined and compared. To reduce various defects in deep drawing process it is necessary to control some parameters of deep drawing process. A deep drawing rig was designed and built for this purpose. Discrete element and finite element coupling simulation and experiment of hot granule medium pressure forming. Analysis of punch velocity dependent process window in. The deep drawing process, as one of the most applicable sheet metal forming process, is widely used in many industries. Figure 5 shows the typical shape characteristics and thickness variations of a. Deep drawing is affected by many factors such as material properties, tool geometry, lubrication etc. Theoretical and experimental analysis of deep drawing. Analysis and experiment this paper reports on the initial stages of a combined experimental and finite element analysis.
Work hardening models and the numerical simulation of the. Detailed experimental and numerical analysis of a cylindrical. Theoretical and experimental analysis of deep drawing cylindrical. Pdf deep drawing process is a significant metal forming process used in the sheet metal forming operations. The process is considered deep drawing when the depth of the drawn part exceeds its diameter. For deep drawing without a blankholder thickness ratio should be at least 3%.
Analysis and experiment this paper reports on the initial stages of a combined experimental and finite element analysis fea. Prediction of wrinkling is a very important process for a deepdrawing operation. 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 depth of the cup created should not exceed the diameter of the blank sheet dieter, 1988 and the thinning should be kept bellow 20% of the original thickness t. 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.
Knightly university of massachusetts amherst follow this and additional works at. The factors affect the deep drawing process may be. The major conclusions drawn from this study are as fallows. The vbhf experiment is under preparation to validate this simulation. Pdf design and analysis of deep drawing process on. Fe analysis has been used to simulate the warm forming process of two parts, a round cup and rectangular pan, using commercial fe codes deform 2d and 3d, respectively. The strains in the radial and circumferential directions have been measured. This paper reports on the initial stages of a combined experimental and finite element analysis fea of a deep drawing process. Under certain conditions, this sliding will cause friction between the tools and the material. Click the select process and material bu on to open the selec on dialog. Rightclick the original analysis tab and select copy rightclick again and select paste. Numerical analysis on the effects of the friction coefficient on the deep drawing of a rail p. The blankholder force was the initial force applied when the punch touched the material. Deep drawing deep drawing deep drawing is defined as a.
The deep drawing process involves a great deal of sliding of the sheet material along the tools. 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. Investigation of a new methodology for the prediction of. 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. Presented contribution deals with force parameters research drawing and blankholding in deepdrawing process of flat bottomed cylindrical cup. Deepdrawing parameters, bioresources 122, 35303545. The objective of this study is to determine the factors influencing a drawing process. There are mainly two methods of deep drawing analysis. In deep drawing process the main objectives are to obtain defect less or minimum defects in product. The objective of this research is to determine the most important factors influencing. Tearing, necking, wrinkling, earing and poor surface appearance are the main failure types that can be seen in deep drawing. It is thus a shape transformation process with material retention.
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. 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. Deep drawing, springback, finite element analysis, aa5754o. Concerning the so called size effects micro deep drawing is widely investigated. The blank drawability has been related both theoretically and experimentally with the initial diameter of the blank and deep draw ing parameters. A copy of the deep drawing analysis is made and placed on a new tab.
Deep drawing for a circular cup a initial stage and. The process was simulated by finite element analysis using a commercial implicit fem package abaqusstandard to establish the base for our following analysis. It was observed that the punch force required for deepdrawing increases with anisotropy in the blank sheets. Investigation of hydrodynamic deep drawing for conical. Apart from its use in many other sectors, it is applied in the automotive industry for the manufacturing of car body parts. 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. Blankingblanking is the process ofcutting the initial sheet coil stockinto round or shaped flatsrequired for deep drawing. Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a. Finite element analysis of deep drawing and springback failure criteria two types of failures were followed through the modeling. 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.
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. 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. Because of these factors, some failures may occur during the process. Finite element simulation of single stage deep drawing. Deep drawing is a vital procedure utilized for making cups from sheet metal in huge quantities. Ruptures in deep drawing, bioresources 112, 46884704. Optimization of deep drawing process for circular cup forming. Deep drawing process analysis and experiment experiment. Experimental analysis can be useful in analyzing the process to determine the process parameters that produce a defect free. In this work, a series of tests were conducted to investigate the deep drawing of aa6111 aluminum alloy at elevated temperatures.
Anshul bindal econtent for aktu manufacturing technology1 duration. 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. The process requires sheet metal with a high thickness ratio, to avoid wrinkling. 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. Various results are illustrated in the details, compared and discussed. Influence of process parameters on deep drawing of aa6111. Deep drawing process is a sheet metal forming process where a. Deep drawing dd is one of the sheet metal forming processes widely used in. Deep drawing is one of the most widely used processes in sheet metal forming. Sheet metal forming is a complex process involving geometric, material and. An optimization technique for combined processes of deepdrawing and ironing has been created in order to improve the total process time and cost in manufacturing procedures of axisymmetric components. The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. In this paper, a finite element fe model is developed for the 3d numerical simulation of deep drawing process parametric analysis.
However, this process is carried out usually under laboratory conditions with a relatively low punch velocity, for example 1 mms. Deep drawing process analysis and experiment experiment nature. Hani aziz ameen ansys deep drawing process 1 ansys analysis of deep drawing process asst. Analysis of an axisymmetric deep drawn part forming using. Compressive stress of the hold down plate in the axial direction radial tensile stress compressive hoops stress material thickens due to circumferential shrinking as it moves in on the cup wall. The process of learning as shown by the mirrordrawing. Pdf analysis of deep drawing process for hemispherical products. Specifically, if the depth of the item created is equal to or greater than its radius, then the metal forming process can be called deep drawing. We also believe that learning about design and analysis of experiments is best achieved by the planning, running, and analyzing of a simple experiment. 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. The strength difference and the initial anisotropy induce uneven. The application of the finite element method to the numerical simulation of the deepdrawing process has evolved in a. Deep drawing provides a great application potential for the manufacturing of parts with complex shapes, even in very small dimensions. Circumferential tensile strain radial tensile strain ironing.
It has been accepted for inclusion in masters theses 1911. 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. Deep drawing process analysis and experiment free download as pdf file. Effects of various parameters in deep drawing process over. To do the deep drawing experiment of brass or any metallic specimen with the help. Pdf experimental and numerical analysis of the deep. The process of learning as shown by the mirrordrawing experiment agnes e. Design and operation of experimental deep drawing rig. This work reports on the initial stages of finite element analysis fea of a deep drawing process. A deep drawing rig was designed and built for this. To find the best group of dimensionless geometric parameters, three scales are evaluated by commercial fe software.
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