Reliability of Isotropic Model in Finite Element Simulation to Predict Wrinkling in Deep Drawing Process

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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Finite-element simulation of the elliptical cup deep drawing process by sheet hydroforming

Finite Elements in Analysis and Design ◽

10.1016/j.finel.2006.09.002 ◽

2007 ◽

Vol 43 (3) ◽

pp. 234-246 ◽

Cited By ~ 25

Author(s):

Takayuki Hama ◽

Tomohiro Hatakeyama ◽

Motoo Asakawa ◽

Hiroyuki Amino ◽

Akitake Makinouchi ◽

...

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Deep Drawing ◽

Drawing Process ◽

Deep Drawing Process ◽

Sheet Hydroforming ◽

Element Simulation

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Finite element simulation on deep-drawing process of magnesium alloy sheet at elevated temperatures

International Journal of Vehicle Design ◽

10.1504/ijvd.2005.007226 ◽

2005 ◽

Vol 39 (1/2) ◽

pp. 154

Author(s):

Shi-Hong Zhang ◽

Kun Zhang ◽

Chuan-Fu Yu ◽

Yi Xu ◽

Ke Yang ◽

...

Keyword(s):

Finite Element ◽

Magnesium Alloy ◽

Finite Element Simulation ◽

Deep Drawing ◽

Elevated Temperatures ◽

Alloy Sheet ◽

Drawing Process ◽

Deep Drawing Process ◽

Magnesium Alloy Sheet ◽

Element Simulation

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Aspects of Finite Element Simulation of Axi-Symmetric Hydromechanical Deep Drawing

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1378793 ◽

2000 ◽

Vol 123 (3) ◽

pp. 411-415 ◽

Cited By ~ 3

Author(s):

M. R. Jensen ◽

L. Olovsson ◽

J. Danckert ◽

K. B. Nielsen

Keyword(s):

Finite Element ◽

Deep Drawing ◽

Finite Difference Approximation ◽

Difference Approximation ◽

Drawing Process ◽

Deep Drawing Process ◽

Explicit Finite Element ◽

Hydromechanical Deep Drawing ◽

Contact Algorithm ◽

Element Simulation

A new approach for the Finite Element modelling of the hydromechanical deep drawing process is evaluated. In the model a Finite Difference approximation of Reynold’s equation is solved for the fluid flow between the blank and the draw die in the flange region. The approach is implemented as a contact algorithm in an explicit Finite Element code, Exhale2D. The developed model is verified against experiments and good agreement is obtained. It is concluded that the developed model is a promising approach for simulating the hydromechanical deep drawing process using the Finite Element Method.

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