Effect of Punch Profile on Thickness Distribution in Hydromechanical Deep Drawing of Conical-Cylindrical Parts

2012 ◽  
Vol 445 ◽  
pp. 143-148 ◽  
Author(s):  
M. Mashhadi ◽  
A. Hashemi ◽  
Mohammad Bakhshi-Jooybari ◽  
A. Gorji
Keyword(s):  
Transition Zone ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Sheet Material ◽  
Radial Pressure ◽  
Simulation Software ◽  
Geometrical Parameters ◽  
Minimum Thickness ◽  
Cylindrical Parts ◽  
St14 Steel

Hydro-mechanical deep drawing assisted with radial pressure (HDDRP) is used in industry to produce complex parts from sheet metals. This process is affected by parameters such as : pressure path, geometrical parameters of punch and die, friction between punch and sheet, etc. Investigating these parameters to acquire optimal parameters to produce the desired part is essential. In this study, the effects of the radius of punch tip and the radius of the transition zone from conical to cylindrical geometry, on forming and thickness distribution of parts have been studied. In performing the investigation, a specific geometry was considered for punch and different radiuses for punch tip and the transition zone were selected. The type of the sheet material examined is St14 steel. First, the process was simulated by the finite element simulation software, ABAQUS 6.9, and then some experiments were done to check the accuracy of the simulations. There is an acceptable conformity between the results. The results showed that the radius of punch tip is more effective than that of the transition zone, so with increasing the radius of punch tip, the minimum thickness increases and thickness distribution becomes more uniform.

scholarly journals Investigation of a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure with Inward Flowing Liquid Process

2018 ◽  
Vol 190 ◽  
pp. 09003
Author(s):  
Maziar Khademi ◽  
Milad Sadegh yazdi ◽  
Mohammad Bakhshi-Jooybari ◽  
Hamid Gorji
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Radial Pressure ◽  
Drawing Ratio ◽  
Cavity Pressure ◽  
Flowing Liquid ◽  
Hydrodynamic Deep Drawing ◽  
Simultaneous Control ◽  
Die Set ◽  
Cylindrical Parts

Hydrodynamic Deep Drawing (HDDRP), the combination of hydroforming and conventional deep drawing, accommodates the advantages of the two processes. A technique, called HDDRP with inward flowing liquid, has been introduced based on the idea of insertion of radial pressure around the blank rim. The radial pressure created on the blank edge, can increase the drawing ratio. Thus, increasing the radial pressure to an amount greater than the cavity pressure, and independent control of these pressures is the basic idea of this research for forming cylindrical parts. To perform the experiments, two independent pumps were used to provide the two pressures independently. The pressure supply system and the die set were designed in a way that provides simultaneous control of the pressures throughout the process. Then, the effects of radial pressure paths on thickness distribution of cylindrical St13 cups were investigated. In addition, a comparison between HDDRP and HDDRP with inward flowing liquid processes has been performed experimentally. Results indicated that using a higher radial pressure than the cavity pressure and controlling their values at any moment of the process enhances the thickness distribution of the formed part in all regions.

Study of the Effect of Material Properties and Sheet Thickness on Formability of Conical Parts in Hydro-Mechanical Deep Drawing Assisted by Radial Pressure

2012 ◽  
Vol 445 ◽  
pp. 149-154 ◽  
Author(s):  
A. Hashemi ◽  
M. Mashhadi ◽  
Mohammad Bakhshi-Jooybari ◽  
A. Gorji
Keyword(s):  
Material Properties ◽  
Deep Drawing ◽  
Distribution Curve ◽  
Thickness Distribution ◽  
Pure Copper ◽  
Sheet Thickness ◽  
Radial Pressure ◽  
Thickness Reduction ◽  
Copper Sheet ◽  
St14 Steel

Conical parts have a lot of usage in industries. Therefore, it is important to form these parts with high accuracy. In sheet forming processes, producing conical parts is one of the most difficult aspects. The two major problems that occur in the production of conical parts are rupturing and wrinkling. Among the forming processes for producing conical parts, the most capable one is hydroforming deep drawing. In this study, the effects of material properties and initial sheet thickness on forming and thickness reduction of the part were examined by using hydro-mechanical deep drawing assisted by radial pressure. For investigating these two parameters, pure copper and st14 steel are used. In experimental evaluation, sheets with thicknesses of 2.5 mm were used. In the simulation study, the thicknesses of 0.5, 1, and 2 mm were also examined. There is a good agreement between experimental and simulation findings. The results showed that for thinner sheets, the thickness reduction is less, and thus, a more uniform thickness distribution curve was obtained. Also, it was illustrated that for St14 steel sheet the thickness distribution curve will be more uniform compared with that of pure copper sheet.

Influencing Factors of AZ31B Sheet Deep Drawing

2011 ◽  
Vol 189-193 ◽  
pp. 88-91
Author(s):  
Jun Gao ◽  
Zhen Ming Yue ◽  
Shu Xia Lin
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Experimental Approach ◽  
Elevated Temperatures ◽  
Heating Temperature ◽  
Thickness Distribution ◽  
Simulation Software ◽  
Forming Limit ◽  
Forming Process ◽  
Specific Strength

Magnesium alloys have been attracting much more attentions due to its low density, high specific strength and its lightweight during the past 30 years. In this paper, the deep drawing performance of AZ31B magnisium alloy sheets at elevated temperature was studied by the experimental approach. The results indicated that the formability of the AZ31B sheets at elevated temperatures could be improved significantly. The best external forming parameters can be obtained such as heating temperature of sheet, die-punch clearance, punch fillet radius, etc. Simulating the forming process by using the numerical simulation software, we investigated the stress-strain distribution, thickness distribution and forming limit, etc. The thickness distribution by the numerical simulation agrees well with the experimental results.

Process analysis of hydrodynamic deep drawing of cone cups assisted by radial pressure

2015 ◽  
Vol 231 (10) ◽  
pp. 1793-1802 ◽  
Author(s):  
Alireza Jalil ◽  
Mohammad Hoseinpour Gollo ◽  
SM Hossein Seyedkashi
Keyword(s):  
Deep Drawing ◽  
Critical Pressure ◽  
Process Analysis ◽  
Fluid Pressure ◽  
Radial Pressure ◽  
Strain Hardening Exponent ◽  
Geometrical Parameters ◽  
Drawing Ratio ◽  
Hydrodynamic Deep Drawing ◽  
Rupture Pressure

Forming of flat sheets into shell conical parts is a complex manufacturing process. Hydrodynamic deep drawing process assisted by radial pressure is a new hydroforming technology in which fluid pressure is applied to the peripheral edge of the sheet in addition to the sheet surface. This technique results in higher drawing ratio and dimensional accuracy, better surface quality, and ability of forming more complex geometries. In this research, a new theoretical model is developed to predict the critical rupture pressure in production of cone cups. In this analysis, Barlat–Lian yield criterion is utilized and tensile instability is considered based on the maximum load applied on the sheet. The proposed model is then validated by a series of experiments. The theoretical predictions are in good agreement with the experimental results. The effects of geometrical parameters and material properties on critical rupture pressure are also studied. The critical pressure is increased with increase in the height ratio, strain hardening exponent, and anisotropy. Higher punch nose radius expands the safe zone. It is shown that the critical pressure decreases for drawing ratios higher than 4.

On the Scale Dependence of Micro Hydromechanical Deep Drawing

2016 ◽  
Vol 725 ◽  
pp. 689-694 ◽  
Author(s):  
Hideki Sato ◽  
Kenichi Manabe ◽  
Tsuyoshi Furushima ◽  
Dong Bin Wei ◽  
Zheng Yi Jiang ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Hydrodynamic Lubrication ◽  
Radial Pressure ◽  
Plasticity Theory ◽  
Minimum Thickness ◽  
Feature Size ◽  
Hydromechanical Deep Drawing ◽  
Compression Effect ◽  
Counter Pressure ◽  
Lubrication Effect

Tooling feature size to minimum thickness becomes small in micro scale products and its ratio affects the deformation behavior in micro sheet forming significantly. In this study, the effect of this relative tooling feature size on drawing characteristics and effects to improve the drawability, such as friction holding effect, hydrodynamic lubrication effect and compression effect by blank edge radial pressure, in micro hydromechanical deep drawing (MHDD) are investigated using plasticity theory and numerical simulation. The results show that the micro drawing characteristics in MHDD can be improved by applying counter pressure. However, the required fluid pressures for friction holding and hydrodynamic lubrication effects increase as the relative punch diameter and/or die shoulder radius to thickness decrease, although the compression effect by radial pressure on the blank edge is independent of the relative tooling feature size.

Influence of Geometrical Parameters on the Maximum Deep Drawing Height of Rectangular Parts

2014 ◽  
Author(s):  
Aarón Rivas Menchi ◽  
Hugo I. Medellín Castillo ◽  
Dirk F. de Lange ◽  
Pedro de J. García Zugasti
Keyword(s):  
Deep Drawing ◽  
Great Influence ◽  
Sheet Thickness ◽  
Geometrical Parameters ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Cylindrical Parts ◽  
High Production ◽  
Cylindrical Cup

The deep drawing process is commonly used in the industry because its ability to produce parts with reduced weight and good mechanical properties at a high production rates. However, the elasto-plastic deformation mechanism of deep drawing is complex and difficult to analyse; this because there are many process parameters and variables involved that affect the quality of final products. Among these variables are the geometric parameters, which have been proved to have a great influence on the process. Theoretical and experimental analyses reported in the literature have been mainly focused on conventional cylindrical cup deep drawing. Few research works have dealt with the deep drawing analysis of non-cylindrical parts, particularly the influence of geometrical parameters on the deep drawing performance. This paper presents an analysis of the effect of geometrical parameters on the allowable deep drawing height (DDH) of rectangular parts before fracture. The aim is to identify the influence of the main geometrical parameters on the DDH, Numerical analyses based on the Finite Element Method (FEM) were used to investigate the influence of geometrical parameters, such as the radii, the metal sheet thickness, and the aspect ratio, among others, on the DDH.

The Research on Friction Impacting on Drawing High-Strength Steel

2011 ◽  
Vol 189-193 ◽  
pp. 1858-1861
Author(s):  
Zhong Jin Wang ◽  
Jian Wei Wang ◽  
Yu Wei Shen
Keyword(s):  
Friction Coefficient ◽  
High Strength Steel ◽  
Thickness Distribution ◽  
High Strength ◽  
Simulation Software ◽  
Friction Condition ◽  
Drawing Process ◽  
Element Simulation ◽  
Cylindrical Parts ◽  
Cylindrical Cup

The paper’s main content is that simulating the process—drawing the high-strength steel-DP500 which is used on automobile to the cylindrical cup through the commercial finite element simulation software—Dynaform. Through the simulation, the author analyzes the effect that friction impacts on drawing high-strength steel. The result is that: if the friction coefficient between the blank and the die declines, it can significantly improve the uniform of the blank’s thickness distribution; it can enlarge the processing range of DP500 steel through decreasing the friction coefficient; the springback is sensitive to the change of the friction condition. Generally speaking, in drawing process, improving the friction coefficient is very important to increase the drawing performance of the cylindrical parts.

Investigation of Forming Cylindrical Parts in a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure With Inward Flowing Liquid

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
Milad Sadegh Yazdi ◽  
Mohammad Bakhshi-Jooybari ◽  
Hamid Gorji ◽  
Mohsen Shakeri ◽  
Maziar Khademi
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Radial Pressure ◽  
Chamber Pressure ◽  
Drawing Ratio ◽  
Forming Force ◽  
Flowing Liquid ◽  
Hydrodynamic Deep Drawing ◽  
Study Results ◽  
Formed Part

Among the sheet hydroforming processes, hydrodynamic deep drawing (HDD) process has been used to form complex shapes and can produce parts with high drawing ratio. Studies showed that radial pressure created on the edge of the sheet can decrease the drawing force and increase drawing ratio. Thus, increasing of radial pressure to an amount greater than chamber pressure, and independent control of these pressures, is the basic idea in this study. In this research, the effect of radial and chamber pressures on formability of St13 and pure copper sheets in the process of hydrodynamic deep drawing assisted by radial pressure (HDDRP) with inward flowing liquid is investigated. Giving that a significant portion of the maximum thinning of the formed part occurs in the beginning of the process, the pressure supply system used in the experimental tests was designed in a way, which provides simultaneous control of the radial and chamber pressures throughout the process. Thickness distribution, forming force, and tensile stresses are the parameters that were evaluated in this study. Results indicated that using a higher radial pressure than the chamber pressure and controlling their values in the initial stages of the process enhances the thickness distribution of the formed part in all regions. A comparison between the thickness distribution and maximum forming force of the formed parts by the HDDRP and HDDRP with inward flowing liquid methods showed that by applying the later method, parts with more uniform thickness distribution and less maximum thinning and forming force can be 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.

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