scholarly journals The Effect of Elevated Temperature on the Drawability of a Circular Deep Drawn Metal Cup

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1303 ◽  
Author(s):  
M. A. M. Basril ◽  
M. Azuddin ◽  
I. A. Choudhury
Keyword(s):  
Stainless Steel ◽  
Elevated Temperature ◽  
Mild Steel ◽  
Deep Drawing ◽  
Optimal Parameter ◽  
Heating Temperature ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Diameter ◽  
Blank Size

Product quality is one of the important aspects in deep drawing practice and the variation in process temperature was claimed to improve the quality. Therefore, in this research, the effect of the heating temperature on the drawability of a circular metal cup has been investigated. Firstly, circular metal cups of aluminium, mild steel and stainless steel were drawn from the blank diameters of 60 mm, 65 mm, and 70 mm. The experiment was conducted at room temperature followed by at 100 °C, 150 °C and 200 °C. The Taguchi method was selected as the design of experiment approach, and L9 (34) array design methodology was adopted in this experimental research. The drawability was measured based on the punching force needed to deform the sheet metal blanks. The deep drawing process was conducted at room, and elevated temperature conditions and the response factor was analysed and compared through the analysis of variance (ANOVA) statistical approach. The results obtained from ANOVA indicate that the blank material has a significant influence on the deep drawing process followed by the blank size, heating temperature and heating technique. The optimal parameter combinations are blank diameter of 60 mm, heating temperature of 200 °C and the die and punch heating technique. Out of the three materials investigated, aluminium has a better drawability compared to mild steel and stainless steel.

scholarly journals Analysis of Deep Drawing Process for Stainless Steel Micro-Channel Array

Materials ◽  
2017 ◽  
Vol 10 (4) ◽  
pp. 423 ◽  
Author(s):  
Tsung-Chia Chen ◽  
Jiang-Cheng Lin ◽  
Rong-Mao Lee
Keyword(s):  
Stainless Steel ◽  
Deep Drawing ◽  
Micro Channel ◽  
Drawing Process ◽  
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.

An Experimental Study on Nonisothermal Deep Drawing Process Using Aluminum and Magnesium Alloys

2008 ◽  
Vol 130 (6) ◽  
Author(s):  
Serhat Kaya ◽  
Giovanni Spampinato ◽  
Taylan Altan
Keyword(s):  
Magnesium Alloys ◽  
Deep Drawing ◽  
Elevated Temperatures ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Punch Velocity ◽  
Forming Temperature ◽  
Tool Set ◽  
Aluminum And Magnesium Alloys ◽  
Blank Size

Weight reduction is one of the major goals in the automotive, appliance, and electronics industries. One way of achieving this goal is to use lightweight alloys such as aluminum and magnesium that have high strength to weight ratios. However, due to their limited formability at room temperature, forming needs to take place at elevated temperatures and mostly under nonisothermal conditions. In this study, nonisothermal deep drawing process using aluminum and magnesium alloys was investigated using a servo motor driven press and a heated tool set. Using the flexibility of the servo press kinematics, blanks were heated in the tool set prior to forming. Temperature-time measurements were made at various blank holder interface pressures in order to determine the required dwell time to heat the blank to the forming temperature. Several lubricants for elevated temperature forming were evaluated using the deep draw test, and a PTFE based film was found to be the best performing lubricant. Deep drawing tests were conducted to determine the process window (maximum punch velocity as functions of blank size and temperature) for Al 5754-O and Mg AZ31-O. Maximum punch velocities of 35 mm/s and 300 mm/s were obtained for the Al and Mg alloys, respectively. Comparisons for the Mg alloy sheets from two different suppliers were made and significant differences in formability were found. Experiments were conducted in order to understand the effect of constant and variable punch velocity and the temperature on the mechanics of deformation. Variable punch velocity is found to improve the thickness distribution of the formed part.

scholarly journals Experimental Evaluation and Finite Element Simulation to Produce Square Cup by Deep Drawing Process

2018 ◽  
Vol 14 (1) ◽  
pp. 39-52 ◽  
Author(s):  
Karem Muhsin Younis ◽  
Adil Shbeeb Jabber ◽  
Mustafa Mohammed Abdulrazaq
Keyword(s):  
Finite Element ◽  
Numerical Analysis ◽  
Process Parameters ◽  
Deep Drawing ◽  
Radial Clearance ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Numerical Predictions ◽  
Die Profile ◽  
Blank Diameter

Deep drawing process to produce square cup is very complex process due to a lot of process parameters which control on this process, therefore associated with it many of defects such as earing, wrinkling and fracture. Study of the effect of some process parameters to determine the values of these parameters which give the best result, the distributions for the thickness and depths of the cup were used to estimate the effect of the parameters on the cup numerically, in addition to experimental verification just to the conditions which give the best numerical predictions in order to reduce the time, efforts and costs for producing square cup with less defects experimentally is the aim of this study. The numerical analysis is used to study the effect of some parameters such as die profile radius, radial clearance between die and punch, blank diameter on the length and thickness  distributions on the cup, dynamic-explicit (ANSYS11) code based on finite element method is utilized to simulate the square deep drawing operation. Experiments were done for comparison and verification the numerical predictions. effective square cup with less defects and acceptable thickness distributions were produced in this study. It is concluded  the most thinning appear in the corner cup due to excessive stretching occur in this region and also it is found the cup thickness and height prediction by numerical analysis and in general in harmony with experimental analysis.

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