Pressure Optimization and Failure Prediction for Deep Drawing Process of Sheet Metal Products: A Case Study

The deep drawing manufacturing process of sheet metal parts with complex shape has increased recently in applications such as in the automotive industry and the household appliances. The trial and error methods commonly used in defining the process parameters, cause high costs and large development times. The computer assisted analysis and simulations are being used more frequently to reduce the cost and development time of a product. The process parameters can be modified and evaluated using these computer simulations before the production is carried out. Therefore the defects of a part can be identified and eliminated, if possible, without the need of the traditional trial and error methods. This paper presents a case study of an industrial component that presented defects (wrinkles at the corners) in its deep drawing process. To eliminate these defects a drawbead was proposed and its optimal location was established using an optimization procedure based on finite element method (FEM). The FEM simulations were validated by measuring the thickness of the fabricated part. To evaluate the elimination of the wrinkle, the thickness of the sheet metal at the critical area was measured in the FEM simulation and compared with the thickness profile before and after the addition of the drawbeads. The results have shown that the design strategy based on FEM can be effectively used as a design tool to eliminate part defects in rectangular deep drawing process.

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Thinning and spring back prediction of sheet metal in the deep drawing process

Materials & Design (1980-2015) ◽

10.1016/j.matdes.2013.07.078 ◽

2014 ◽

Vol 53 ◽

pp. 797-808 ◽

Cited By ~ 23

Author(s):

H. Zein ◽

M. El Sherbiny ◽

M. Abd-Rabou ◽

M. El shazly

Keyword(s):

Sheet Metal ◽

Deep Drawing ◽

Drawing Process ◽

Spring Back ◽

Deep Drawing Process

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A study of vibro-acoustic behaviour variation of thin sheet metal components manufactured through deep drawing process

Applied Acoustics ◽

10.1016/j.apacoust.2019.04.015 ◽

2019 ◽

Vol 153 ◽

pp. 110-126

Author(s):

Vamsi Krishna Balla ◽

Laurens Coox ◽

Elke Deckers ◽

Francesco Greco ◽

Bert Pluymers ◽

...

Keyword(s):

Sheet Metal ◽

Deep Drawing ◽

Thin Sheet ◽

Drawing Process ◽

Deep Drawing Process ◽

Acoustic Behaviour ◽

Thin Sheet Metal

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Study of the Parameters of Deep Drawing Process Based on the Simulation of Dynaform

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.249-250.51 ◽

2012 ◽

Vol 249-250 ◽

pp. 51-58

Author(s):

Qing Wen Qu ◽

Tian Ke Sun ◽

Shao Qing Wang ◽

Hong Juan Yu ◽

Fang Li

Keyword(s):

Friction Coefficient ◽

Sheet Metal ◽

Deep Drawing ◽

Drawing Process ◽

Blank Holder Force ◽

Blank Holder ◽

Deep Drawing Process ◽

Drawing Die ◽

Drawing Speed

A simulation of deep drawing process on the sheet metal was done by using Dynaform, the influence of blank holder force, deep drawing speed and friction coefficient on the forming speed of sheet metal in the deep drawing process were got. The forming speed of sheet metal determines the quality of deep drawing, in the deep drawing process the blank holder force and the deep drawing speed are controllable parameters, the friction coefficient can be intervened and controlled, and it’s a manifestation of the interaction of all parameters, the main factors which influence the friction coefficient just have blank holder force, deep drawing speed and lubrication except the material. The conclusion of this study provides the basic data for the analysis of the lubrication of mould, the study of lubricant and the prediction of the service life of deep drawing die.

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FEM Simulation of Anisotropic Parameters Influencing the Earing in Sheet Metal Deep Drawing Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.88-89.638 ◽

2011 ◽

Vol 88-89 ◽

pp. 638-641 ◽

Cited By ~ 1

Author(s):

Lei Chen

Keyword(s):

Finite Element ◽

Finite Element Model ◽

Sheet Metal ◽

Deep Drawing ◽

Fem Simulation ◽

Element Model ◽

Drawing Process ◽

Deep Drawing Process ◽

Material Characteristics

Earing is often undesirable in the production of deep drawn containers because it results in a nonuniform cup height. A finite element model for earring analysis is developed considering only the flange area of the sheet. It was found that the draw-in depth of the flange increases with the increase of the r value, and it remains invariable when r value is larger than 2. With the increase of the r value, the max thickness decreases and the min thickness increases. If △r>0, four earings are formed. If △r =0, the material characteristics in all the planar directions are same. The flange uniformly flows into the die cavity, no earing is formed. If △r<0, four earings are formed. The earing distribution is dominated by r0, r45 and r90. Both r and △r have much effect on the earing distribution.

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