scholarly journals b EXPERIMENTAL AND FINITE ELEMENT ANALYSIS OF SQUARE DEEP DRAWING PROCESS FOR LAMINATED STEEL-BRASS SHEET METALS

2020 ◽  
Vol 20 (1) ◽  
pp. 12-24
Author(s):  
Hani Aziz Ameen
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Low Carbon Steel ◽  
High Strength ◽  
Experimental Tests ◽  
Drawing Process ◽  
Low Carbon ◽  
Element Analysis ◽  
Blank Holder ◽  
Deep Drawing Process

In this paper, the drawability of two-layer (steel-brass) sheets to produce square cup, is investigated through numerical simulations, and experimental tests. Each material has its own benefits and drawbacks in terms of its physical, chemical and mechanical properties, so that the point of this investigation is taking the benefits of different materials, like (low density, high strength and resistibility of corrosion), at the same time and in a one part. ANSYS18 software is used to simulate the deep drawing process of laminated sheet. The deep drawing processes for square cup were carried out under various blank holder loads with different lubrication conditions (dry and lubricant) and with variable layer arrangement. The materials were low carbon steel st1008 and brass CuZn30 sheets with thickness of 0.5mm0and 0.58mm respectively. The thickness of laminated sheet blank was 1.1 mm and its diameter was 83 mm. The drawn cups with less imperfections and satisfactory thickness distribution were formed in this study. It is concluded the greatest thinning appear in the corner of the cup near the punch radius due to extreme stretching take place in this area. Experimental forming load, blank holder load, and thickness distribution are compared with simulation results. Good agreement between experimental and numerical is evident.

scholarly journals Simulation of Metal Flow to Investigate the Application of Antilock Brake Mechanic System in Deep Drawing Process of Cup

2013 ◽  
Vol 789 ◽  
pp. 367-372 ◽  
Author(s):  
Susila Candra ◽  
I. Made Londen Batan ◽  
Agus Sigit Pramono ◽  
Bambang Pramujati
Keyword(s):  
Deep Drawing ◽  
Metal Flow ◽  
Low Carbon Steel ◽  
Drawing Process ◽  
Low Carbon ◽  
Drawing Force ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Cylindrical Cup

This paper presents the importance of simulation of metal flow in deep drawing process which employs an antilock brake mechanic system. Controlling the force and friction of the blank holder is imperative to assure that the sheet metal is not locked on the blank holder, and hence it flows smoothly into the die. The simulation was developed based on the material displacement, deformation and deep drawing force on flange in the radial direction, that it is controlled by blank holder with antilock brake mechanic system. The force to blank holder was applied periodically and the magnitude of force was kept constant during simulation process. In this study, the mechanical properties of the material were choses such that they equivalent to those of low carbon steel with its thickness of 0.2 mm. The diameter and the depth of the cylindrical cup-shaped product were 40 mm and 10 mm, respectively. The simulation results showed that the application of antilock brake mechanic system improves the ability to control the material flow during the drawing process, although the maximum blank holder force of 13000 N was applied. The optimum condition was found when the drawing process was performed using blank holder force of 3500 N, deep drawing force of 7000 N, friction coefficient of 0.25 and speed of punch stroke of 0.84 mm/sec. This research demonstrated that an antilock brake mechanic system can be implemented effectively to prevent cracking in 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.

Analytical and numerical investigation of wrinkling limit diagram in deep drawing of two-layer sheets with experimental verification

2021 ◽  
pp. 146442072098531
Author(s):  
AH Bamdad ◽  
R Hashemi
Keyword(s):  
Material Properties ◽  
Deep Drawing ◽  
Analytical Approach ◽  
Experimental Tests ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Layer Stacking ◽  
The Impact

Wrinkling, which is primarily caused by insufficient blank holder force, is a significant issue that induces inconsistencies in forming parts, particularly in the deep drawing process. In this article, an investigation of the wrinkling in the deep drawing process of two-layer sheets is performed through an analytical approach, numerical method, and experimental tests. Increasing in the blank holder force, the process is under control by the proposed algorithm. Consequently, it aims to find the minimum required blank holder force to avoid wrinkling. The energy technique is utilized to predict the wrinkling in the analytical approach. Similarly, finite element simulations are implemented to investigate the effect of forming parameters on wrinkling. The experimental tests are performed to verify the analytical and numerical results. The impact of the material properties and stacking sequences (lay-up) on blank holder force and forming force are studied. Results show that the optimum blank holder force is dependent on the material properties, blank geometry, and layer stacking sequences. Also, a good agreement between analytical, numerical, and experimental results is achieved.

scholarly journals Effect of Tool Geometry Parameters on the Formability of a Camera Cover in the Deep Drawing Process

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3993
Author(s):  
Thanh Trung Do ◽  
Pham Son Minh ◽  
Nhan Le
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Metal Flow ◽  
Sheet Thickness ◽  
Side Wall ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting. However, the optimization of tools including the die and punch parameters leads to a reduction of the defects and improves the quality of the products. In this paper, the formability of the camera cover by aluminum alloy A1050 in the deep drawing process was examined relating to the tool geometry parameters based on numerical and experimental analyses. The results showed that the thickness was the smallest and the stress was the highest at one of the bottom corners where the biaxial stretching was the predominant mode of deformation. The problems of the thickening at the flange area, the stretching at the side wall and the splitting at the bottom corners could be prevented when the tool parameters were optimized that related to the thickness and stress. It was clear that the optimal thickness distribution of the camera cover was obtained by the design of tools with the best values—with the die edge radius 10 times, the pocket radius on the bottom of the die 5 times, and the punch nose radius 2.5 times the sheet thickness. Additionally, the quality of the camera cover was improved with a maximum thinning of 25% experimentally, and it was within the suggested maximum allowable thickness reduction of 45% for various industrial applications after optimizing the tool geometry parameters in the deep drawing process.

Blank holder force optimisation strategy in deep drawing process

2007 ◽  
Vol 1 (2) ◽  
pp. 226 ◽  
Author(s):  
Hossam H. Gharib ◽  
Abdalla S. Wifi ◽  
Maher Y.A. Younan ◽  
Ashraf O. Nassef
Keyword(s):  
Deep Drawing ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process

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

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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