Analysis of Size-Effects in the Miniaturized Deep Drawing Process

2007 ◽  
Vol 344 ◽  
pp. 791-798 ◽  
Author(s):  
H. Justinger ◽  
Gerhard Hirt

With the increasing trend towards miniaturization and the enhanced demand for small components, reliable processes for mass production are needed. Today the deep drawing process is already used to produce large numbers of small parts (diameter < 1 mm) at low costs per part. But a better understanding of the process in relation to miniaturization is required to improve process stability, because several aspects of the process change when scaled down. For example, product accuracy and process parameters can be influenced by changing the ratio of surface to volume or the ratio of grain size to foil thickness. For the analysis of these effects experiments with geometrically scaled deep drawing tool sets from 8 mm to 1 mm punch diameter have been carried out, using CuZn37 foils in different annealed conditions and a foil thickness ranging from 0.3 mm to 0.04 mm. Additionally, the deep drawing process is simulated via FE-methods to consider influences that cannot be measured using the available experimental setup, such as temperature conditions resulting from the heat generated due to plastic dissipation and friction.

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3993
Author(s):  
Thanh Trung Do ◽  
Pham Son Minh ◽  
Nhan Le

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.


Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi

1993 ◽  
Vol 115 (2) ◽  
pp. 224-229 ◽  
Author(s):  
K. Yamaguchi ◽  
K. Kanayama ◽  
M. H. Parsa ◽  
N. Takakura

A new deep drawing process of sheet metals is developed to facilitate small-lot production of deep cups with large drawing ratio. In this process, unlike the conventional deep drawing method, a few drawn cups are always stacked on the punch and used as a part of punch for the subsequent deep drawing of a given blank. Before drawing a new blank, a drawn cup which is in contact with the punch is stripped off. The repetition of such stripping and drawing operations makes it possible to carry out both the first-stage drawing and the subsequent slight redrawings in one drawing operation using only one pair of punch and die. In this paper, this new deep drawing process is applied to the production of tapered cups and the main feature of the process is shown.


2014 ◽  
Vol 53 ◽  
pp. 797-808 ◽  
Author(s):  
H. Zein ◽  
M. El Sherbiny ◽  
M. Abd-Rabou ◽  
M. El shazly

Author(s):  
Hossam H. Gharib ◽  
Abdalla S. Wifi ◽  
Maher Y.A. Younan ◽  
Ashraf O. Nassef

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