Initial Blank Optimization in Multilayer Deep Drawing Process Using GONNS

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
M. R. Morovvati ◽  
B. Mollaei-Dariani ◽  
M. Haddadzadeh
Keyword(s):  
Deep Drawing ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Training Data ◽  
Drawing Process ◽  
Thickness Strain ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Deformation Force ◽  
Blank Shape

The initial blank in the deep drawing process has a simple shape. After drawing, its perimeter shape becomes very complex. If the initial blank shape is designed in such a way that it is formed into the desired shape after the drawing process, not only does it reduces the time of trimming process but it also decreases the raw material needed substantially. In this paper, the genetically optimized neural network system (GONNS) is proposed as a tool to predict the initial blank shape for the desired final shape. Artificial neural networks (ANNs) represent the final blank shape after a training process and genetic algorithms find the optimum initial blank. The finite element method is employed for simulating the multilayer plate deep drawing process to provide training data for ANN. The GONNS results were verified through experiment in which the error was found to be about 0.2 mm. At last, variations of deformation force, thickness distribution, and thickness strain distribution were investigated using optimum blank. The results show 12% reduction in deformation force and more uniform thickness distribution as well as more consistent thickness strain distribution in the optimum blank shape.

Blank Design by ANN in Bimetallic Deep Drawing

2009 ◽  
Author(s):  
M. R. Morovati Mamaghani ◽  
B. M. Dariani ◽  
M. Haddadzade
Keyword(s):  
Neural Network ◽  
Deep Drawing ◽  
Training Data ◽  
Raw Material ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Blank Design ◽  
Novel Approach ◽  
Blank Shape

The present paper deals with the initial blank design of bimetallic parts obtained by deep drawing process. Normally in deep drawing, the initial blank has a simple shape and after drawing, its perimeter shape will become very complex and has considerable influences on the forming results. If the initial blank shape is designed in such a way that is formed into the desired shape after the drawing process, not only it reduces the time of trimming process, but also decreases the drawing force and the raw material needed substantially. The present paper proposes a novel approach to initial blank optimization in multilayer deep drawing. The Finite Element Method (FEM) is employed for simulating multilayer plate deep drawing process to provide training data for Artificial Neural Network (ANN). The aim of the neural network is to predict the initial blank shape for the desired final shape. The FEM results were verified through experiment.

A Study on Initial Blank Design to Minimize Earing in Multi-Stage Deep Drawing Process for Rectangular Cup Using High Strength Steel Material

2013 ◽  
Vol 652-654 ◽  
pp. 1971-1975
Author(s):  
Pan Liu ◽  
Tae Wan Ku ◽  
Beom Soo Kang
Keyword(s):  
Deep Drawing ◽  
Sheet Material ◽  
Simulation Models ◽  
Drawing Process ◽  
Element Analysis ◽  
Normal Anisotropy ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Multi Stage ◽  
Blank Shape

Multi-stage deep drawing process for rectangular cups with extreme aspect ratio using finite element analysis is performed. The process is mainly consists of four forming stages including blanking, drawing, ironing and trimming. However, main deformation of the rectangular cup is completed during the drawing-ironing procedure. Tool design and blank modification for the multi-stage deep drawing process are presented. To consider the deep drawing and the ironing operations, the multi-stage deep drawing process is applied to obtain the rectangular cup by using each numerical simulation models from first to fifth drawing. Based on the design results of the initial blank, the multi-stage deep drawing process is performed, but it is shown that severe earing phenomenon is occurred at the upper flange part. To solve the severe deformation at the upper flange due to normal anisotropy of the used sheet material, initial blank modification is carried out. The simulation results for the rectangular cup are compared with the final configuration before and after the modification of the blank shape. The predicted result is confirmed that the modified blank shape not only improve the quality of a deep-drawn product but also reduce the cost of production.

Study of Earing Defect during Deep Drawing Process with Finite Element Simulation

2015 ◽  
Vol 639 ◽  
pp. 91-98 ◽  
Author(s):  
Ravikant Patel ◽  
Harshit Dave ◽  
Harit Raval
Keyword(s):  
Finite Element ◽  
Mild Steel ◽  
Finite Element Simulation ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Initial Blank ◽  
Element Simulation ◽  
Blank Shape

Deep drawing is one of widely used sheet metal working process in industries to produce cup shaped components at a very high rate. In deep drawing process, a sheet metal blank form cylindrical components by process in which central portion of sheet is pressed into die opening to draw the metal into desired shape without folding the corners. Earing is one of the major defects observed during deep drawing process due to anisotropic nature of sheet metal. Earing is defined as formation of waviness on uppermost portion of deep drawn cup. Knowledge about ear formation in deep drawing process allows a prior modification of process which can result in defect free final product with financial saving and time. The initial blank shape used in present study is circular in nature.The objective of present study aims to produce parts which are earing defect free. Earing can be reduced by modifying the initial blank shape such as use of non circular blank as in present study. Efforts have been made to study the earing problem in deep drawing of cylindrical cups by finite element modeling software HYPERWORK-12 and Incremental RADIOSS as solver. The blank material selected for study is EN10130FeP06 mild steel sheet of 1mm thickness as it has wide application in fabricating automobile parts. Mechanical parameters of mild steel are incorporated in finite element simulation of deep drawing process. Significant earing was observed at rolling and transverse direction on deformed cup form circular blank. Modification of initial blank is done to reduce the earing defect. The results show significant reduction of % earing height and drawing load as well as improvement in maximum thickness variations.

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.

Blank shape optimization in the deep drawing process by sun method

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Shape Optimization ◽  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape Optimization ◽  
Blank Shape

scholarly journals b EXPERIMENTAL AND FINITE ELEMENT ANALYSIS OF SQUARE DEEP DRAWING PROCESS FOR LAMINATED STEEL-BRASS SHEET METALS

2020 ◽  
Vol 20 (1) ◽  
pp. 12-24
Author(s):  
Hani Aziz Ameen
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Low Carbon Steel ◽  
High Strength ◽  
Experimental Tests ◽  
Drawing Process ◽  
Low Carbon ◽  
Element Analysis ◽  
Blank Holder ◽  
Deep Drawing Process

In this paper, the drawability of two-layer (steel-brass) sheets to produce square cup, is investigated through numerical simulations, and experimental tests. Each material has its own benefits and drawbacks in terms of its physical, chemical and mechanical properties, so that the point of this investigation is taking the benefits of different materials, like (low density, high strength and resistibility of corrosion), at the same time and in a one part. ANSYS18 software is used to simulate the deep drawing process of laminated sheet. The deep drawing processes for square cup were carried out under various blank holder loads with different lubrication conditions (dry and lubricant) and with variable layer arrangement. The materials were low carbon steel st1008 and brass CuZn30 sheets with thickness of 0.5mm0and 0.58mm respectively. The thickness of laminated sheet blank was 1.1 mm and its diameter was 83 mm. The drawn cups with less imperfections and satisfactory thickness distribution were formed in this study. It is concluded the greatest thinning appear in the corner of the cup near the punch radius due to extreme stretching take place in this area. Experimental forming load, blank holder load, and thickness distribution are compared with simulation results. Good agreement between experimental and numerical is evident.

Optimum blank shape design in deep drawing process using a new boundary updating formula

2021 ◽  
Author(s):  
Hamidreza Gharehchahi ◽  
Mohammad-Javad Kazemzadeh-Parsi ◽  
Ahmad Afsari ◽  
Mehrdad Mohammadi
Keyword(s):  
Deep Drawing ◽  
Shape Design ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Blank Shape

Effect of Geometries of Die/Blank Holder and Punch Radii in Angular Deep-Drawing Dies on DP Steel Formability

2015 ◽  
Vol 813-814 ◽  
pp. 269-273 ◽  
Author(s):  
P. Venkateshwar Reddy ◽  
S. Hari Prasad ◽  
Perumalla Janaki Ramulu ◽  
Sirish Battacharya ◽  
Daya Sindhu Guptha
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Frictional Coefficient ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Dp Steel ◽  
Punch Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Drawing Dies

In recent days deep-drawing is one of the most important methods used for sheet metal forming. The geometries of die/blank holder and punch are one of the parameters for deep-drawing. This paper presents an attempt to determine the effect of different geometries of die/blank holder, punch radii and blank holding force on deep drawing process for the formability of DP Steel of 1mm sheet. The numerical simulations are performed for deep drawing of cylindrical cups at a constant frictional coefficient of 0.12 and different blank holding forces of 10, 15 and 20kN are used. For numerical simulation PAM STAMP 2G a commercial FEM code in which Hollomon’s power law and Hills 1948 yield’s criterion is used. The die/blank holder profile used with an angles of α=0°, 12.5°, 15° and die/punch profile with a radii of R= 6 and 8mm were simulated to determine the influence of punch force and thickness distribution on the limit drawing ratio. The aim of this study is to investigate the effect of tool geometries on drawability of the deep-drawing process.

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