Abstract: Earing defect in drawing process is highly undesirable not only because it adds on an additional trimming operation but also because the uneven material flow demands extra care. The objective of this work is to study the earing problem in the Deep Drawing of circular cup and to optimize the blank shape to reduce the earing. A finite element model is developed for 3-D numerical simulation of cup forming process in ABAQUS. Extra-deep-drawing (EDD) steel sheet has been used for simulation. Properties and tool design parameters were used as input for simulation. Earing was observed in the simulated cup and it was measured at various angles with respect to rolling direction. To reduce the earing defect initial blank shape was modified with the help of anisotropy coefficient. Modified blanks showed notable reduction in earing.
Abstract: In the present work, forming limit diagrams and strain
distribution profile diagrams for extra deep drawing steel at room and
elevated temperatures have been determined experimentally by
conducting stretch forming experiments by using designed and
fabricated warm stretchforming tooling setup. With the help of
forming Limit Diagrams (FLDs) and strain, distribution profile
diagrams the formability of Extra Deep Drawing steel has been
analyzed and co-related with mechanical properties like strain
hardening COEFFICIENT (n) and normal anisotropy (r−). Mechanical
properties of EDD steel from room temperature to 4500C were
determined and discussed the impact of temperature on the properties
like work hardening exponent (n) anisotropy (r-) and strength
coefficient of the material. In addition, the fractured surfaces after
stretching have undergone the some metallurgical investigations and
attempt has been made to co-relate with the formability of EDD steel
sheets. They are co-related and good agreement with FLDs at various
temperatures.
Abstract: Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.
Abstract: The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys.
The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restreint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.
Abstract: Because of high ductility, aluminum alloys, have been widely used as an important base of metal forming industries. But the main week point of these alloys is their low strength so in forming them with conventional methods like deep drawing, hydro forming, etc have been always faced with problems like fracture during of forming process. Because of this, recently using of explosive forming method for forming of these plates has been recommended. In this paper free explosive forming of A2024 aluminum alloy is numerically simulated and during it, explosion wave propagation process is studied. Consequences of this simulation can be effective in prediction of quality of production. These consequences are compared with an experimental test and show the superiority of this method to similar methods like hydro forming and deep drawing.
Abstract: Springback is a significant problem in the sheet metal
forming process. When the tools are released after the stage of
forming, the product springs out, because of the action of the internal
stresses. In many cases the deviation of form is too large and the
compensation of the springback is necessary. The precise prediction
of the springback of product is increasingly significant for the design
of the tools and for compensation because of the higher ratio of the
yield stress to the elastic modulus.
The main object in this paper was to study the effect of the
anisotropy on the springback for three directions of rolling: 0°, 45°
and 90°. At the same time, we highlighted the influence of three
different metallic materials: Aluminum, Steel and Galvanized steel.
The original of our purpose consist on tests which are ensured by
adapting a U-type stretching-bending device on a tensile testing
machine, where we studied and quantified the variation of the
springback according to the direction of rolling. We also showed the
role of lubrication in the reduction of the springback.
Moreover, in this work, we have studied important characteristics
in deep drawing process which is a springback. We have presented
defaults that are showed in this process and many parameters
influenced a springback.
Finally, our results works lead us to understand the influence of
grains orientation with different metallic materials on the springback
and drawing some conclusions how to concept deep drawing tools. In
addition, the conducted work represents a fundamental contribution
in the discussion the industry application.
Abstract: This paper gives an overview of a deep drawing
process by pressurized liquid medium separated from the sheet by a
rubber diaphragm. Hydroforming deep drawing processing of sheet
metal parts provides a number of advantages over conventional
techniques. It generally increases the depth to diameter ratio possible
in cup drawing and minimizes the thickness variation of the drawn
cup. To explore the deformation mechanism, analytical and
numerical simulations are used for analyzing the drawing process of
an AA6061-T4 blank. The effects of key process parameters such as
coefficient of friction, initial thickness of the blank and radius
between cup wall and flange are investigated analytically and
numerically. The simulated results were in good agreement with the
results of the analytical model. According to finite element
simulations, the hydroforming deep drawing method provides a more
uniform thickness distribution compared to conventional deep
drawing and decreases the risk of tearing during the process.
Abstract: In this paper back-propagation artificial neural
network (BPANN) is employed to predict the limiting drawing ratio
(LDR) of the deep drawing process. To prepare a training set for
BPANN, some finite element simulations were carried out. die and
punch radius, die arc radius, friction coefficient, thickness, yield
strength of sheet and strain hardening exponent were used as the
input data and the LDR as the specified output used in the training of
neural network. As a result of the specified parameters, the program
will be able to estimate the LDR for any new given condition.
Comparing FEM and BPANN results, an acceptable correlation was
found.
Abstract: Today, Hydroforming technology provides an
attractive alternative to conventional matched die forming, especially
for cost-sensitive, lower volume production, and for parts with
irregular contours. In this study the critical fluid pressures which lead
to rupture in the workpiece has been investigated by theoretical and
finite element methods. The axisymmetric analysis was developed to
investigate the tearing phenomenon in cylindrical Hydroforming
Deep Drawing (HDD). By use of obtained equations the effect of
anisotropy, drawing ratio, sheet thickness and strain hardening
exponent on tearing diagram were investigated.
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.
Abstract: Low carbon deep drawing steel DC 01 according to EN 10130-91 was nitrooxidized in dissociated ammonia at 580°C/45 min and consequently oxidised at 380°C/5 min in vapour of distilled water. Material after nitrooxidation had 54 % increase of yield point, 34 % increase of strength and 10-times increased resistance to atmospheric corrosion in comparison to the material before nitrooxidation. The microstructure of treated material consisted of thin ε-phase layer connected to layer containing precipitated massive needle shaped Fe4N - γ' nitrides. This layer passed to a diffusion layer consisting of fine irregular shaped Fe16N2 - α'' nitrides regularly dispersed in ferritic matrix. Fatigue properties were examined under bending load with frequency of 20 kHz and sinusoidal symmetric cycle. The results confirmed positive influence of nitrooxidation on fatigue properties as fatigue limit of treated material was double in comparison to untreated material.
Abstract: This study was aimed to explain the influence of surface roughness of the drawbead on non-symmetry deep drawing cold rolled steel sheet to improve the drawability of cold rolled steel sheet. The variables used in this study included semi-circle drawbead with 3 levels of surface roughness which are 6.127 mm Ra, 0.963 mm Ra and 0.152 mm Ra and cold rolled steel sheet according to 3 grades of the JIS standards which are SPCC, SPCE and SPCD with the thickness of 1.0 mm and the blankholder force which is 50% of the drawing force and the depth of 50 mm. According to the test results, when there was the increase in the surface roughness of drawbead, there would be the increase in deep drawing force, especially the SPCC cold rolled steel sheet. This is similar to the increase in the equivalent strain and the wall thickness distribution when the surface roughness of the drawbead increased. It could be concluded that the surface roughness of drawbead has an influence on deep drawing cold rolled steel sheet, especially the drawing force, the equivalent strain and the wall thickness distribution.
Abstract: In this paper back-propagation artificial neural
network (BPANN) with Levenberg–Marquardt algorithm is
employed to predict the limiting drawing ratio (LDR) of the deep
drawing process. To prepare a training set for BPANN, some finite
element simulations were carried out. die and punch radius, die arc
radius, friction coefficient, thickness, yield strength of sheet and
strain hardening exponent were used as the input data and the LDR
as the specified output used in the training of neural network. As a
result of the specified parameters, the program will be able to
estimate the LDR for any new given condition. Comparing FEM and
BPANN results, an acceptable correlation was found.
Abstract: In this paper a low cost knowledge base system (KBS)
framework is proposed for design of deep drawing die and procedure
for developing system modules. The task of building the system is
structured into different modules for major activities of design of
deep drawing die. A manufacturability assessment module of the
proposed framework is developed to check the manufacturability of
deep drawn parts. The technological knowledge is represented by
using IF- THEN rules and it is coded in AutoLISP language. The
module is designed to be loaded into the prompt area of AutoCAD.
The cost of implementation of proposed system makes it affordable
for small and medium scale sheet metal industries.
Abstract: Intelligent deep-drawing is an instrumental research field in sheet metal forming. A set of 28 different experimental data have been employed in this paper, investigating the roles of die radius, punch radius, friction coefficients and drawing ratios for axisymmetric workpieces deep drawing. This paper focuses an evolutionary neural network, specifically, error back propagation in collaboration with genetic algorithm. The neural network encompasses a number of different functional nodes defined through the established principles. The input parameters, i.e., punch radii, die radii, friction coefficients and drawing ratios are set to the network; thereafter, the material outputs at two critical points are accurately calculated. The output of the network is used to establish the best parameters leading to the most uniform thickness in the product via the genetic algorithm. This research achieved satisfactory results based on demonstration of neural networks.
Abstract: A lot of research made during these last 15 years
showed that the quantification of the springback has a significant role
in the industry of sheet metal forming. These studies were made with
the objective of finding techniques and methods to minimize or
completely avoid this permanent physical variation. Moreover, the
use of steel and aluminum alloys in the car industry and aviation
poses every day the problem of the springback. The determination in
advance of the quantity of the springback allows consequently the
design and manufacture of the tool. The aim of this paper is to study
experimentally the influence of the blank holder force BHF and the
radius of curvature of the die on the springback and their influence on
the strain in various zone of specimen.
The original of our purpose consist on tests which are ensured by
adapting a U-type stretching-bending device on a tensile testing
machine, where we studied and quantified the variation of the
springback according to displacement.