Simulation-Based Designed Process for Optimization of Blank Shape in the Deep Drawing Process

2021 ◽  
pp. 745-759
Author(s):  
Rahul Rai ◽  
Vijay Gautam
Keyword(s):  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Simulation Based ◽  
Blank Shape

Blank shape optimization in the deep drawing process by sun method

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Shape Optimization ◽  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape Optimization ◽  
Blank Shape

A Study on Initial Blank Design to Minimize Earing in Multi-Stage Deep Drawing Process for Rectangular Cup Using High Strength Steel Material

2013 ◽  
Vol 652-654 ◽  
pp. 1971-1975
Author(s):  
Pan Liu ◽  
Tae Wan Ku ◽  
Beom Soo Kang
Keyword(s):  
Deep Drawing ◽  
Sheet Material ◽  
Simulation Models ◽  
Drawing Process ◽  
Element Analysis ◽  
Normal Anisotropy ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Multi Stage ◽  
Blank Shape

Multi-stage deep drawing process for rectangular cups with extreme aspect ratio using finite element analysis is performed. The process is mainly consists of four forming stages including blanking, drawing, ironing and trimming. However, main deformation of the rectangular cup is completed during the drawing-ironing procedure. Tool design and blank modification for the multi-stage deep drawing process are presented. To consider the deep drawing and the ironing operations, the multi-stage deep drawing process is applied to obtain the rectangular cup by using each numerical simulation models from first to fifth drawing. Based on the design results of the initial blank, the multi-stage deep drawing process is performed, but it is shown that severe earing phenomenon is occurred at the upper flange part. To solve the severe deformation at the upper flange due to normal anisotropy of the used sheet material, initial blank modification is carried out. The simulation results for the rectangular cup are compared with the final configuration before and after the modification of the blank shape. The predicted result is confirmed that the modified blank shape not only improve the quality of a deep-drawn product but also reduce the cost of production.

Optimum blank shape design in deep drawing process using a new boundary updating formula

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad-Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Deep Drawing ◽  
Shape Design ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape

Initial Blank Optimization in Multilayer Deep Drawing Process Using GONNS

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
M. R. Morovvati ◽  
B. Mollaei-Dariani ◽  
M. Haddadzadeh
Keyword(s):  
Deep Drawing ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Training Data ◽  
Drawing Process ◽  
Thickness Strain ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Deformation Force ◽  
Blank Shape

The initial blank in the deep drawing process has a simple shape. After drawing, its perimeter shape becomes very complex. If the initial blank shape is designed in such a way that it is formed into the desired shape after the drawing process, not only does it reduces the time of trimming process but it also decreases the raw material needed substantially. In this paper, the genetically optimized neural network system (GONNS) is proposed as a tool to predict the initial blank shape for the desired final shape. Artificial neural networks (ANNs) represent the final blank shape after a training process and genetic algorithms find the optimum initial blank. The finite element method is employed for simulating the multilayer plate deep drawing process to provide training data for ANN. The GONNS results were verified through experiment in which the error was found to be about 0.2 mm. At last, variations of deformation force, thickness distribution, and thickness strain distribution were investigated using optimum blank. The results show 12% reduction in deformation force and more uniform thickness distribution as well as more consistent thickness strain distribution in the optimum blank shape.

Blank Design by ANN in Bimetallic Deep Drawing

2009 ◽  
Author(s):  
M. R. Morovati Mamaghani ◽  
B. M. Dariani ◽  
M. Haddadzade
Keyword(s):  
Neural Network ◽  
Deep Drawing ◽  
Training Data ◽  
Raw Material ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Blank Design ◽  
Novel Approach ◽  
Blank Shape

The present paper deals with the initial blank design of bimetallic parts obtained by deep drawing process. Normally in deep drawing, the initial blank has a simple shape and after drawing, its perimeter shape will become very complex and has considerable influences on the forming results. If the initial blank shape is designed in such a way that is formed into the desired shape after the drawing process, not only it reduces the time of trimming process, but also decreases the drawing force and the raw material needed substantially. The present paper proposes a novel approach to initial blank optimization in multilayer deep drawing. The Finite Element Method (FEM) is employed for simulating multilayer plate deep drawing process to provide training data for Artificial Neural Network (ANN). The aim of the neural network is to predict the initial blank shape for the desired final shape. The FEM results were verified through experiment.

Numerical Simulation in Deep Drawing of Cylindrical Cup with Circular Diving Equally Small Holes on Edge of Circle Blank

2010 ◽  
Vol 148-149 ◽  
pp. 769-773
Author(s):  
Yu Qing Shi
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Metal Forming ◽  
Failure Modes ◽  
Small Hole ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape ◽  
Cylindrical Cup ◽  
Small Holes

Deep-drawing is one of the most important methods to form sheet metal ,but wrinkling and fracture are the main failure modes in sheet-metal forming. Blank shape is important for deep-drawing because of an effective way to promote deep formability sheet metal .This paper presents an attempt to determine the effect of circle blank with circular diving equally small hole on edge of circle blank on the fracture and wrinkling and was investigated using 08Al sheet metal .The circular blank with small hole of diameter = was analyzed to eliminate wrinkling and fracture in deep-drawing .The aim of this study is to investigate the circular diving equally small hole on edge of circle blank on formability in the deep-drawing process and to obtain useful date from the industrial field .The experiment show that limit formability promote with punching small holes on circle blank in deep-drawing process.

Study of Earing Defect during Deep Drawing Process with Finite Element Simulation

2015 ◽  
Vol 639 ◽  
pp. 91-98 ◽  
Author(s):  
Ravikant Patel ◽  
Harshit Dave ◽  
Harit Raval
Keyword(s):  
Finite Element ◽  
Mild Steel ◽  
Finite Element Simulation ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Element Simulation ◽  
Blank Shape

Deep drawing is one of widely used sheet metal working process in industries to produce cup shaped components at a very high rate. In deep drawing process, a sheet metal blank form cylindrical components by process in which central portion of sheet is pressed into die opening to draw the metal into desired shape without folding the corners. Earing is one of the major defects observed during deep drawing process due to anisotropic nature of sheet metal. Earing is defined as formation of waviness on uppermost portion of deep drawn cup. Knowledge about ear formation in deep drawing process allows a prior modification of process which can result in defect free final product with financial saving and time. The initial blank shape used in present study is circular in nature.The objective of present study aims to produce parts which are earing defect free. Earing can be reduced by modifying the initial blank shape such as use of non circular blank as in present study. Efforts have been made to study the earing problem in deep drawing of cylindrical cups by finite element modeling software HYPERWORK-12 and Incremental RADIOSS as solver. The blank material selected for study is EN10130FeP06 mild steel sheet of 1mm thickness as it has wide application in fabricating automobile parts. Mechanical parameters of mild steel are incorporated in finite element simulation of deep drawing process. Significant earing was observed at rolling and transverse direction on deformed cup form circular blank. Modification of initial blank is done to reduce the earing defect. The results show significant reduction of % earing height and drawing load as well as improvement in maximum thickness variations.

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