Theoretical, numerical and experimental investigation of hydro-mechanical deep drawing of steel/polymer/steel sandwich sheets

2018 ◽  
Vol 233 (5) ◽  
pp. 1529-1546 ◽  
Author(s):  
Majid Fazlollahi ◽  
Mohammad Reza Morovvati ◽  
Bijan Mollaei Dariani
Keyword(s):  
Deep Drawing ◽  
Fluid Pressure ◽  
Chamber Pressure ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Forming Force ◽  
Limit Drawing Ratio ◽  
Deep Drawing Process ◽  
Sandwich Sheet ◽  
Sandwich Sheets

Fabricating flat sandwich sheets into components with a required shape and dimensions is a challenging job in the metal forming field. In this article, hydro-mechanical deep drawing was used for sandwich sheet forming. The aim of the work is to achieve higher drawing ratio of these sheets. Theoretical, numerical and experimental analysis of the hydro-mechanical deep drawing of sandwich sheets was carried out. Separated layers theory method is used for theoretical analysis of the process. Then, the numerical simulation of the process was developed by finite element method. The effect of core layer thickness on the forming force of the sandwich sheet and effective parameters of the process such as strain and forming force was investigated. Experimental works were conducted on the steel/polymer/steel sandwich sheets by a hydro-mechanical deep drawing die. A good agreement was observed between theoretical, numerical and experimental results. The safe zone of fluid pressure for achieving a part without rupture was obtained. It was shown that the limit drawing ratio is increased by increasing the pressure but after a particular point, the limit drawing ratio is decreased by increasing the chamber pressure. It was also observed that maximum drawing ratio for achieving a part without rupture in the hydro-mechanical deep drawing process is higher than conventional deep drawing process.

Deep Drawing with a Fluid Pressure Assisted Blankholder

1992 ◽  
Vol 206 (4) ◽  
pp. 247-252 ◽  
Author(s):  
S Yossifon ◽  
J Tirosh
Keyword(s):  
Deep Drawing ◽  
Pressure Range ◽  
Fluid Pressure ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Ductile Rupture ◽  
Deep Drawing Process ◽  
Working Zone ◽  
Upper Limits ◽  
Flange Wrinkling

The feasibility of replacing the rigid blankholder in the conventional deep drawing process with a ‘soft’ hydrostatic fluid pressure is examined. The recommended fluid pressure range (the ‘working zone’) which guarantees a sound product in different circumstances is presented. The locus curve for possible failure by wrinkling of the flange and the locus curve for possible ductile rupture along the wall provide the lower and the upper limits respectively of the ‘working zone’. These loci are found by a systematic series of deep drawing tests with different constant fluid pressure blankholders for three kinds of materials (copper, aluminium and stainless steel) at various thicknesses and friction conditions. The influence of the friction coefficient, the drawing ratio and the workpiece wall thickness on the blankholder fluid pressure needed to suppress flange wrinkling becomes evident experimentally.

Investigation of consecutive two-stage hydrodynamic deep drawing of aluminum cylindrical cups

2021 ◽  
pp. 095440542110622
Author(s):  
Seyed Hassan Alavi Hashemi ◽  
Seyed Mohammad Hossein Seyedkashi
Keyword(s):  
Deep Drawing ◽  
Diameter Ratio ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Effective Parameters ◽  
Limit Drawing Ratio ◽  
Deep Drawing Process ◽  
Hydrodynamic Deep Drawing ◽  
Element Simulation ◽  
Simulation Results

In the deep drawing process, achieving a higher drawing ratio has always been considered by researchers. In this study, a new concept of hydrodynamic deep drawing with two consecutive stages without additional operations such as annealing is proposed to increase the limit drawing ratio of the cups. The effective parameters were investigated numerically and experimentally in the forming of Al1200 cylindrical cups. At first, the desired value of punch diameter ratio was determined based on finite element simulation results and was utilized to increase the cup formability. Next, the effects of pressure paths on the cup thickness, separation, and rupture were studied in each forming stage. The cup formability was investigated based on a new proposed framework to obtain the maximum possible limiting drawing ratio, and the desired conditions were determined. Finally, a cup was formed with a high drawing ratio of 3.4 which was a good achievement in comparison with the literature.

Production of Tapered Cups by Sequential Deep Drawing of Sheet Metals Using Drawn Cups as a Part of Punch

1993 ◽  
Vol 115 (2) ◽  
pp. 224-229 ◽  
Author(s):  
K. Yamaguchi ◽  
K. Kanayama ◽  
M. H. Parsa ◽  
N. Takakura
Keyword(s):  
Deep Drawing ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Sheet Metals ◽  
Deep Drawing Process ◽  
Drawing Method

A new deep drawing process of sheet metals is developed to facilitate small-lot production of deep cups with large drawing ratio. In this process, unlike the conventional deep drawing method, a few drawn cups are always stacked on the punch and used as a part of punch for the subsequent deep drawing of a given blank. Before drawing a new blank, a drawn cup which is in contact with the punch is stripped off. The repetition of such stripping and drawing operations makes it possible to carry out both the first-stage drawing and the subsequent slight redrawings in one drawing operation using only one pair of punch and die. In this paper, this new deep drawing process is applied to the production of tapered cups and the main feature of the process is shown.

Identification for Technological Capabilities of Titanium and Aluminum Alloys in Deep Drawing Process

2020 ◽  
Vol 299 ◽  
pp. 628-633 ◽  
Author(s):  
S.I. Feoktistov ◽  
Kyaw Zayar Soe
Keyword(s):  
Aluminum Alloys ◽  
Deep Drawing ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Work Piece ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Variable Parameters ◽  
Deep Drawing Process ◽  
The Moment

The paper describes a method which has been developed for obtaining the limiting drawing ratio of titanium and aluminum alloys, and determines the moment of failure of the work-piece. This method is based not only on the use of Forming Limit Diagram (FLD) in predicting the failure of the blank, but also the using method of variable parameters of elasticity in determining the stress-strain state in deep drawing process.

scholarly journals Multi Draw Radius Die Design for Increases in Limiting Drawing Ratio

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 870 ◽  
Author(s):  
Wiriyakorn Phanitwong ◽  
Sutasn Thipprakmas
Keyword(s):  
Deep Drawing ◽  
Material Flow ◽  
Rolling Direction ◽  
Die Design ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Limiting Drawing Ratio ◽  
Proper Design ◽  
Main Barrier

As a major sheet metal process for fabricating cup or box shapes, the deep drawing process is commonly applied in various industrial fields, such as those involving the manufacture of household utensils, medical equipment, electronics, and automobile parts. The limiting drawing ratio (LDR) is the main barrier to increasing the formability and production rate as well as to decrease production cost and time. In the present research, the multi draw radius (MDR) die was proposed to increase LDR. The finite element method (FEM) was used as a tool to illustrate the principle of MDR based on material flow. The results revealed that MDR die could reduce the non-axisymmetric material flow on flange and the asymmetry of the flange during the deep drawing process. Based on this material flow characteristic, the cup wall stretching and fracture could be delayed. Furthermore, the cup wall thicknesses of the deep drawn parts obtained by MDR die application were more uniform in each direction along the plane, at 45°, and at 90° to the rolling direction than those obtained by conventional die application. In the present research, a proper design for the MDR was suggested to achieve functionality of the MDR die as related to each direction along the plane, at 45°, and at 90° to the rolling direction. The larger draw radius positioned for at 45° to the rolling direction and the smaller draw radius positioned for along the plane and at 90° to the rolling direction were recommended. Therefore, by using proper MDR die application, the drawing ratio could be increased to be 2.75, an increase in LDR of approximately 22.22%.

scholarly journals Study on micro extra deep drawing process with ultrahigh fluid pressure and press motion controls

2015 ◽  
Vol 21 ◽  
pp. 09016
Author(s):  
Hideki Sato ◽  
Daiki Kondo ◽  
Ken-ichi Manabe ◽  
Kuniyoshi Ito
Keyword(s):  
Deep Drawing ◽  
Fluid Pressure ◽  
Drawing Process ◽  
Deep Drawing Process

Effect of Geometries of Die/Blank Holder and Punch Radii in Angular Deep-Drawing Dies on DP Steel Formability

2015 ◽  
Vol 813-814 ◽  
pp. 269-273 ◽  
Author(s):  
P. Venkateshwar Reddy ◽  
S. Hari Prasad ◽  
Perumalla Janaki Ramulu ◽  
Sirish Battacharya ◽  
Daya Sindhu Guptha
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Frictional Coefficient ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Dp Steel ◽  
Punch Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Drawing Dies

In recent days deep-drawing is one of the most important methods used for sheet metal forming. The geometries of die/blank holder and punch are one of the parameters for deep-drawing. This paper presents an attempt to determine the effect of different geometries of die/blank holder, punch radii and blank holding force on deep drawing process for the formability of DP Steel of 1mm sheet. The numerical simulations are performed for deep drawing of cylindrical cups at a constant frictional coefficient of 0.12 and different blank holding forces of 10, 15 and 20kN are used. For numerical simulation PAM STAMP 2G a commercial FEM code in which Hollomon’s power law and Hills 1948 yield’s criterion is used. The die/blank holder profile used with an angles of α=0°, 12.5°, 15° and die/punch profile with a radii of R= 6 and 8mm were simulated to determine the influence of punch force and thickness distribution on the limit drawing ratio. The aim of this study is to investigate the effect of tool geometries on drawability of the deep-drawing process.

On-Line Thinning Measurement in the Deep Drawing Process

2002 ◽  
Vol 124 (2) ◽  
pp. 420-425 ◽  
Author(s):  
Moshe Berger ◽  
Eyal Zussman
Keyword(s):  
Deep Drawing ◽  
Process Model ◽  
Thickness Distribution ◽  
Strain Analysis ◽  
Longitudinal Axis ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Round Cross Section ◽  
Deep Drawing Process ◽  
Acoustic Coupling

The conventional deep drawing process is limited to a certain Limit Drawing Ratio (LDR), beyond which localized wall thinning and rupture occur. One way to increase the LDR is to try to capture the onset of necking and to adjust process parameters in order to delay or avoid necking. This paper describes a method for monitoring the wall thickness of a cup during the deep drawing process. Measurement utilizes a noncontact ultrasound gauge that is located orthogonally to the drawn cup’s wall and is immersed in oil to create an acoustic coupling. Monitoring is based upon a deep drawing process model using a thin blank with a round cross-section. Thickness distribution along a longitudinal axis is predicted and is used as a trajectory to track in-process thinning variations that may lead to tearing. The robustness of the measurement system is examined by applying the technique in different experiments. Results show that in-process measurements correlate well with grid strain analysis of a formed sheet metal part.

Sign in / Sign up

Export Citation Format

Share Document