Finite Element Modeling of Deep Drawing of Coated Sheet

2012 ◽  
Vol 430-432 ◽  
pp. 1302-1305
Author(s):  
Xiao Bing Zhang
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Nickel Coating ◽  
Drawing Process ◽  
Nose Radius ◽  
Danger Zone ◽  
Friction Coefficients ◽  
Deep Drawing Process ◽  
Substrate Steel ◽  
Coated Sheet

The deep drawing process is one of the important sheet-metal forming processes. Using this operation, many parts are manufactured in various industries. With this regard, the numerical simulations of a kind of coated sheet deep-drawing process were conducted using LS-DYNA in this paper. The model takes into account the coating/substrate composite may delaminate or crack during drawing, the combination of coating and substrate was defined as tied with failure contact. The results of the simulations revealed that the substrate (steel sheet) and the nickel coating did not delaminate at the interface. Furthermore, it was found that the punch-nose radius is the danger zone for the break and at this zone, the thickness of the coating was thinner than the substrate, some experiments were done to validate the simulated results. At last, the influences of friction coefficients were analyzed and the result that greater friction coefficients will lead to increase the tendency of crack was attained.

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.

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.

Investigating the Effects of the Friction Coefficient and Tool Geometry on the Cup Thickness in the Deep Drawing Process of SPXI250 Alloy

2013 ◽  
Author(s):  
Iman Rostamsowlat ◽  
Ahmad Afsari ◽  
Maziar Janghorban
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Deep Drawing ◽  
The Other ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process ◽  
Simulation Results ◽  
Thickness Variations

In this paper, effects of friction coefficient and tool geometry on the thickness variations of a cylindrical cup were studied. Blank is made of SPXI250 alloy sheet which was analyzed by Finite Element Method (FEM). This not been studied yet. Finite Element modeling of the deep drawing process was conducted using ABAQUS/EXPLICIT software. A set of appropriate die and punch were designed for experimental tests. The results of the simulation showed that a change in the friction coefficient of the die-blank interface leads to a significant changes in the cup thickness. Moreover, the results revealed that the influence of die nose radius on the final cup thickness variations is greater than that of the punch nose radius. The simulation results of this study were compared with the experimental results and those of the other investigators’. The comparisons of the experimental and simulation results with those of the other researchers were so satisfactory.

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 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.

scholarly journals Review on Different Hardening Models for Computation of Deep Drawing Process Simulation

2020 ◽  
Author(s):  
Araveeti C S Reddy
Keyword(s):  
Magnesium Alloy ◽  
Process Simulation ◽  
Deep Drawing ◽  
Metal Forming ◽  
Computational Modelling ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Hardening Model ◽  
Magnesium Alloy Az31 ◽  
Hardening Models

we address herein various hardening models and their suitability in computational modelling of deepdrawing process wherein magnesium alloy AZ31 as blank material. insight on all basic and advanced hardeningmodels. The basic models as well as advanced models were illustrated in usefulness of them in metal forming. Itis purely depends on the researcher to select the appropriate hardening model for extracting the real computationalbehavior resembling the true hardening property.

Multi-Stage Cold Deep Drawing of Pure Titanium Square Cup

2015 ◽  
Vol 651-653 ◽  
pp. 1072-1077 ◽  
Author(s):  
Yasunori Harada ◽  
Minoru Ueyama
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Pure Titanium ◽  
Oxide Coating ◽  
Drawing Process ◽  
Forming Process ◽  
Titanium Sheet ◽  
Cold Forming ◽  
Deep Drawing Process ◽  
Multi Stage

This paper deals with the formability of pure titanium sheet in square cup deep drawing. Pure titanium has very excellent corrosion resistance. In the metal forming process, pure titanium has very good ductility in cold forming. The normal anisotropy of pure titanium is very high. Therefore, the property is suitable to the sheet metal forming, such as deep drawing process. However, the most important problem is that the occurrence of seizure becomes remarkable in severe forming operations. Many investigations on the effect of processing conditions on the seizure of titanium were carried out. In the present study, the formability of pure titanium sheet in square cup deep drawing was investigated. For the prevention, pure titanium sheets were treated by heat oxide coating. The fresh and clean titanium is not in direct contact with the die during the forming due to the existence of the oxide layer. The material was pure titanium sheets of the JIS grade 2. The initial thickness of the blank was 0.5 mm in thickness. In the deep drawing process, the sheets were employed and a flat sheet blank is formed into a square by a punch. Forming of sheet by multi-stage deep drawing was tried. Various cups were drawn by exchanging the punch and die. The die was taper without a blankholder in the subsequent stages. The effects of the intermediate annealing and tool shape on the occurrence of seizure in square cup deep drawing were also examined. The square cups were successfully drawn by heat oxide coating. The coating of titanium sheet has sufficient ability in preventing the seizure in multi-stage deep drawing operation. The results of the present study revealed that the pure titanium square cups were successfully formed by using heat oxide coating treatment.

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.

Numerical Simulation in Deep Drawing of Cylindrical Cup with Circular Diving Equally Small Holes on Edge of Circle Blank

2010 ◽  
Vol 148-149 ◽  
pp. 769-773
Author(s):  
Yu Qing Shi
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Metal Forming ◽  
Failure Modes ◽  
Small Hole ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape ◽  
Cylindrical Cup ◽  
Small Holes

Deep-drawing is one of the most important methods to form sheet metal ,but wrinkling and fracture are the main failure modes in sheet-metal forming. Blank shape is important for deep-drawing because of an effective way to promote deep formability sheet metal .This paper presents an attempt to determine the effect of circle blank with circular diving equally small hole on edge of circle blank on the fracture and wrinkling and was investigated using 08Al sheet metal .The circular blank with small hole of diameter = was analyzed to eliminate wrinkling and fracture in deep-drawing .The aim of this study is to investigate the circular diving equally small hole on edge of circle blank on formability in the deep-drawing process and to obtain useful date from the industrial field .The experiment show that limit formability promote with punching small holes on circle blank in deep-drawing process.

Sign in / Sign up

Export Citation Format

Share Document