Experimental Study of Drawing Load Curves in Forming Conical Parts by Hydroforming and Conventional Deep Drawing Processes

2011 ◽  
Vol 291-294 ◽  
pp. 556-560 ◽  
Author(s):  
Salman Norouzi ◽  
Amir Reza Yaghoubi ◽  
Mohammad Bakhshi-Jooybari ◽  
Abdolhamid Gorji
Keyword(s):  
Experimental Study ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Pure Copper ◽  
Experimental Program ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Load Variation ◽  
Hydroforming Process

Since conical parts have wide applications in the industry and forming these parts is one of the most complex and difficult fields in sheet metal forming processes, the study on different methods in forming these parts can be useful. Hydroforming and conventional multistage deep drawing are two deep drawing processes which have been used to form conical parts. Hydroforming deep drawing is one of the special deep drawing processes which have been introduced in order to overcome some inherent problems in the conventional deep drawing with rigid tools. In the present work, an experimental program has been carried out to compare the drawing load variation and maximum drawing load in forming pure copper conical-cylindrical cups with the thickness of 2.5 mm by hydroforming and conventional multistage deep drawing processes. The results of the study demonstrate that drawing load variation is more uniform in the forming of conical parts by hydroforming deep drawing process. The maximum drawing load for drawing copper blank occurs at a higher amount in hydroforming process.

Thickness Distribution in Conical Parts Formed by Hydroforming and Conventional Multistage Deep Drawing Processes

2011 ◽  
Vol 189-193 ◽  
pp. 2884-2887
Author(s):  
Abdolhamid Gorji ◽  
Amir Reza Yaghoubi ◽  
Mohammad Bakhshi-Jooybari ◽  
Salman Norouzi
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Pure Copper ◽  
Experimental Program ◽  
Drawing Process ◽  
Blank Holder ◽  
Sheet Surface ◽  
Two Stages ◽  
Explosive Forming

Forming conical parts is one of the difficult fields in sheet metal forming processes. Because of low contact area of the sheet with the punch in the initial stages of forming, too much tension applied to the sheet that it causes bursting. Furthermore, since the major part of the sheet surface between the blank holder and punch tip is free, wrinkles appears on the wall of the drawn parts. These parts are normally formed in industry by processes such as spinning, explosive forming or multistage deep drawing. Hydroforming deep drawing is one of the special deep drawing processes which have been introduced in order to overcome some inherent problems in the conventional deep drawing with rigid tools. In the present work, an experimental program has been carried out to form and compare the forming pure copper conical-cylindrical cups by hydroforming and conventional multistage deep drawing processes. The conical parts in conventional deep drawing process formed in two stages. The results of the study demonstrate that thickness distribution are more uniform in the parts formed by hydroforming compared to conventional multi stages deep drawing processes.

Simulation Study of Deep Drawing Process

2020 ◽  
Vol 977 ◽  
pp. 139-147
Author(s):  
Jaber Abu Qudeiri ◽  
Aiman Ziout ◽  
Muneir Alsayyed ◽  
Ammar Alzarooni ◽  
Faris Safieh ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Deformation Behaviour ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Optimal Values

Deep drawing process is one of the important processes in sheet metal forming. One of the challenge that faces the deep drawing process is selecting the optimal values of process parameters for the deep drawing process. In order to find the optimum values of these parameters, it is necessary to study their influence on the deformation behaviour of the sheet metal. This paper develops a simulation model for deep drawing process based on Simufact sheet metal forming module to study the effect process parameters on the deep-drawing characteristics. The study also obtained the distribution of strain on the drawn product. Three process parameters are considered in this study namely, punch radius, die radius and clearance, the effect of these process parameter on the required force as well as on the quality of the product are investigated.

New Approach for Wrinkle Prediction in Deep Drawing Process

2015 ◽  
Vol 639 ◽  
pp. 459-466
Author(s):  
Fei Han ◽  
Ranko Radonjic
Keyword(s):  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Optical Measurement ◽  
Thin Sheet ◽  
Drawing Process ◽  
New Approach ◽  
Deep Drawing Process ◽  
Forming Technology ◽  
Buckling Test

Due to the extensive use of thin sheet metals to reduce weight of car bodies, wrinkling is becoming a more common and one of the most undesirable defects in sheet metal forming processes. Recent experiments at the Institute for Metal Forming Technology (IFU), University of Stuttgart, indicated that the buckling test using modified specimens can enhance accuracy for the predication of wrinkling [1]. In this paper a new method to predict the onset of the wrinkling will be introduced, and results of this test will be compared with real deep drawing parts. The wrinkle heights will be considered an evaluated regarding to results obtained by an optical measurement system.

Study of factors affecting Springback in Sheet Metal Forming and Deep Drawing Process

2018 ◽  
Vol 5 (2) ◽  
pp. 4353-4358 ◽  
Author(s):  
Radha Krishna Lal ◽  
Vikas Kumar Choubey ◽  
J.P. Dwivedi ◽  
Shravan Kumar
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Factors Affecting

Optimization of Deep Drawing Processes Using Statistical Design of Experiments

1996 ◽  
Author(s):  
Dietrich Bauer ◽  
Regine Krebs
Keyword(s):  
Mathematical Model ◽  
Analysis Of Variance ◽  
Orthogonal Array ◽  
Deep Drawing ◽  
Metal Forming ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Metal Forming Process

Abstract For a deep drawing process some important controllable variables (factors) upon the maximum drawing force are analyzed to find a setting adjustment for these process factors that provides a very low force for the metal forming process. For this investigation an orthogonal array L18 with three-fold replication is used. To find the optimum of the process, the experimental results are analyzed in accordance with the robust-design-method according to Taguchi (Liesegang et. al., 1990). For this purpose, so-called Signal-to-Noise-ratios are calculated. The analysis of variance for this S/N-ratios leads to a mathematical model for the deep drawing process. This model allows to find the pressumed optimal settings of the investigated factors. In the following, a confirmation experiment is carried out by using these optimal settings. The maximum drawing force of the confirmation experiment does not correspond with the confidence interval, which was calculated by analysis of variance techniques. So the predicted optimum of the process does not lead to a metal forming process with very low deep drawing force. The comparison with a full factorial plan shows that there are interactions between the investigated factors. These interactions could not be discovered by the used orthogonal array. Thus the established mathematical model does not describe the relation between the factors and deep drawing force in accordance with the practical deep drawing conditions.

scholarly journals A Consistent Relationship between the Stress and Plastic Strain Components and Its Application in Deep Drawing Process

2017 ◽  
Vol 2017 ◽  
pp. 1-6 ◽  
Author(s):  
Yong Zhang ◽  
Qing Zhang ◽  
Xianrong Qin ◽  
Yuantao Sun
Keyword(s):  
Plastic Strain ◽  
Deep Drawing ◽  
Metal Forming ◽  
Yield Criterion ◽  
Flow Rule ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Dimensional Changes ◽  
Consistent Relationship ◽  
Strain Components

As von Mises yield criterion and associated flow rule (AFR) are widely applied in metal forming field, a semitotal deformation consistent relationship between the stress and plastic strain components and the rule of dimensional changes of metal forming processes in a plane-stress state are obtained on the basis of them in this paper. The deduced consistent relationship may be easily used in forming interval of the workpiece. And the rule of dimensional changes can be understood through three plastic strain incremental circles on which the critical points can be easily determined on the same basis. Analysis of stress and plastic strain evolution of aluminum warm deep drawing process is conducted, and the advantage of nonisothermal warm forming process is revealed, indicating that this method has the potential in practical large deformation applications.

scholarly journals Advanced Techniques used in Numerical Simulation for Deep-drawing Process

2019 ◽  
Vol 290 ◽  
pp. 03012
Author(s):  
Valentin Oleksik ◽  
Radu Breaz ◽  
Gabriel Racz ◽  
Paul Dan Brindasu ◽  
Octavian Bologa
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Deep Drawing ◽  
Metal Forming ◽  
Inverse Analysis ◽  
Direct Analysis ◽  
Simulation Software ◽  
Drawing Process ◽  
Mathematical Apparatus ◽  
Deep Drawing Process

The present paper analyse the main characteristics of the numerical simulation by finite element method of the deep-drawing processes. Also the authors’ highlights the mathematical apparatus and the calculus method used for numerical simulations of metal forming processes in many of the current simulation software. The authors present the capabilities of the inverse analysis, direct analysis, implicit analysis (for springback simulation) and the optimisation analysis applied to explicit formulations.

Experimental investigation into a new hybrid-forming process: Incremental stretch drawing

2016 ◽  
Vol 232 (3) ◽  
pp. 475-486 ◽  
Author(s):  
Puneet Tandon ◽  
Om Namah Sharma
Keyword(s):  
Experimental Investigation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Lead Time ◽  
Drawing Process ◽  
Forming Process ◽  
Setup Cost ◽  
Deep Drawing Process ◽  
Incremental Sheet Metal Forming

Incremental sheet metal forming is an evolving process, which is suitable for the production of limited quantities of sheet metal components. The main advantages of this process over conventional forming processes are reduced setup cost and manufacturing lead time, as it eliminates the need of special purpose dies, improves formability, reduces forming forces, and provides process flexibility. The objective of this work is to investigate a new hybrid-forming process, which intends to combine incremental sheet metal forming with deep drawing process and has been named as “incremental stretch drawing.” A number of setups and fixtures were developed to carry out experiments to achieve incremental stretch drawing and understand the mechanism of the process. This process addresses some of the challenges of incremental sheet metal forming, that is, limited formability in terms of forming depth, especially at steeper wall angles and subsequent thinning of sheet. It is observed that the proposed process is able to reduce thinning as much as about 300%, considering same forming depth for incremental sheet metal forming and incremental stretch drawing processes. Improvement in formability, in terms of forming depths, also has been observed to be near about 100% in particular cases.

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