Finite Element Simulation of Multi-Stage Deep Drawing Processes and Comparison with Experimental Results
The plastic forming process of sheet plate takes an
important place in forming metals. The traditional techniques of tool
design for sheet forming operations used in industry are experimental
and expensive methods. Prediction of the forming results,
determination of the punching force, blank holder forces and the
thickness distribution of the sheet metal will decrease the production
cost and time of the material to be formed. In this paper, multi-stage
deep drawing simulation of an Industrial Part has been presented
with finite element method. The entire production steps with
additional operations such as intermediate annealing and springback
has been simulated by ABAQUS software under axisymmetric
conditions. The simulation results such as sheet thickness
distribution, Punch force and residual stresses have been extracted in
any stages and sheet thickness distribution was compared with
experimental results. It was found through comparison of results, the
FE model have proven to be in close agreement with those of
experiment.
[1] J. Cao, Sh. Li, Z. C. Xia, S. C. Tang, 2001, "Analysis of an axisymmetric
deep-drawn part forming using reduced forming steps", Journal of
Material Processing Technology. Vol 117, pp. 193-200.
[2] H. K. Kim, S. K. Hong, 2007, "FEM-based optimum design of multistage
deep drawing process of molybdenum sheet", Journal of Material
Processing Technology. Vol 184, pp. 354-362.
[3] D.K. Min, B.H. Jeon, H.J. Kim, N. Kim, 1995, "A study on process
improvements of multi-stage deep-drawing by the finite-element
method", J. Mater. Process. Technol. Vol 54, pp. 230-238.
[4] S. H. Kim, S. H. Kim, H. Huh, 2002, "Tool design in a multi-stage
drawing and ironing process of a rectangular cup with a large aspect
ratio using finite element analysis", Int. J. Mach. Tool Manuf. Vol 42 ,
pp. 863-875.
[5] T. W. Ku, B. K. Ha, W. J. Song, B. S. Kang, S. M. Hwang, 2002, "Finite
element analysis of multi-stage deep drawing process for high-precision
rectangular case with extreme aspect ratio", J. Mater. Process. Technol.
Vol 130-131, pp. 128-134.
[6] J. P. Fan, C. Y. Tang, C. P. Tsui, L. C. Chan, T. C. Lee, 2006, "3D finite
element simulation of deep drawing with damage development",
International Journal of Machine Tools & Manufacture, Vol 46, pp.
1035-1044.
[7] CINDAS/USAF CRDA Handbooks Operation Purdue University,
"Aerospace Structural Metals Handbook", 1997, Vol 3.
[8] S. Kobayashi, T. Altan. "Metal forming and the finite element method".
New York: Oxford University Press; 1989.
[9] ASM International, "Atlas of Stress-Strain Curves", USA, Ohio, 2002, p.
299.
[10] D. F. Eary, E. A. Reed. 1958, "Techniques of Press-working Sheet
Metal", 2nd edition. New Jersey: Prentice Hall, Englewood Cliffs. P.
156.
[1] J. Cao, Sh. Li, Z. C. Xia, S. C. Tang, 2001, "Analysis of an axisymmetric
deep-drawn part forming using reduced forming steps", Journal of
Material Processing Technology. Vol 117, pp. 193-200.
[2] H. K. Kim, S. K. Hong, 2007, "FEM-based optimum design of multistage
deep drawing process of molybdenum sheet", Journal of Material
Processing Technology. Vol 184, pp. 354-362.
[3] D.K. Min, B.H. Jeon, H.J. Kim, N. Kim, 1995, "A study on process
improvements of multi-stage deep-drawing by the finite-element
method", J. Mater. Process. Technol. Vol 54, pp. 230-238.
[4] S. H. Kim, S. H. Kim, H. Huh, 2002, "Tool design in a multi-stage
drawing and ironing process of a rectangular cup with a large aspect
ratio using finite element analysis", Int. J. Mach. Tool Manuf. Vol 42 ,
pp. 863-875.
[5] T. W. Ku, B. K. Ha, W. J. Song, B. S. Kang, S. M. Hwang, 2002, "Finite
element analysis of multi-stage deep drawing process for high-precision
rectangular case with extreme aspect ratio", J. Mater. Process. Technol.
Vol 130-131, pp. 128-134.
[6] J. P. Fan, C. Y. Tang, C. P. Tsui, L. C. Chan, T. C. Lee, 2006, "3D finite
element simulation of deep drawing with damage development",
International Journal of Machine Tools & Manufacture, Vol 46, pp.
1035-1044.
[7] CINDAS/USAF CRDA Handbooks Operation Purdue University,
"Aerospace Structural Metals Handbook", 1997, Vol 3.
[8] S. Kobayashi, T. Altan. "Metal forming and the finite element method".
New York: Oxford University Press; 1989.
[9] ASM International, "Atlas of Stress-Strain Curves", USA, Ohio, 2002, p.
299.
[10] D. F. Eary, E. A. Reed. 1958, "Techniques of Press-working Sheet
Metal", 2nd edition. New Jersey: Prentice Hall, Englewood Cliffs. P.
156.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:60709", author = "A. Pourkamali Anaraki and M. Shahabizadeh and B. Babaee", title = "Finite Element Simulation of Multi-Stage Deep Drawing Processes and Comparison with Experimental Results", abstract = "The plastic forming process of sheet plate takes an
important place in forming metals. The traditional techniques of tool
design for sheet forming operations used in industry are experimental
and expensive methods. Prediction of the forming results,
determination of the punching force, blank holder forces and the
thickness distribution of the sheet metal will decrease the production
cost and time of the material to be formed. In this paper, multi-stage
deep drawing simulation of an Industrial Part has been presented
with finite element method. The entire production steps with
additional operations such as intermediate annealing and springback
has been simulated by ABAQUS software under axisymmetric
conditions. The simulation results such as sheet thickness
distribution, Punch force and residual stresses have been extracted in
any stages and sheet thickness distribution was compared with
experimental results. It was found through comparison of results, the
FE model have proven to be in close agreement with those of
experiment.", keywords = "Deep drawing, Finite element method, Simulation.", volume = "6", number = "1", pages = "260-5", }