Comparative Study of Analytical Expressions to Estimate the Deep Drawing Force of Cylindrical and Rectangular Parts

2016 ◽  
Author(s):  
Aarón Rivas Menchi ◽  
Hugo I. Medellín Castillo ◽  
Dirk F. de Lange ◽  
Pedro de J. García Zugasti
Keyword(s):  
Deep Drawing ◽  
Prediction Performance ◽  
Process Efficiency ◽  
Equivalent Diameter ◽  
Drawing Process ◽  
Drawing Force ◽  
Deep Drawing Process ◽  
The Press ◽  
Cylindrical Parts ◽  
Analytical Expressions

The deep drawing process has been widely used in the industry because it eliminates costly operations such as welding and machining. However, there are many parameters involved that affect the quality of the final products. One of the main parameters of the deep drawing process is the maximum deep drawing force (DDF) or drawing load, which is the maximum force required to perform a particular deep drawing operation. This maximum DDF is needed to define the required capacity of the press, and to calculate the deep drawing work and the process efficiency. Several analytical expressions to estimate the maximum DDF have been proposed in the literature, particularly for cylindrical parts. However, few research works have focused on analyzing the prediction performance of these expressions. In this paper, the performance of different analytical expressions to estimate the maximum DDF of cylindrical and rectangular parts, is evaluated and compared. Initially, several expressions proposed by different researches for the maximum DDF of cylindrical parts are presented. Then, these expressions are transformed into new expressions for the maximum DDF of rectangular parts by using different concepts of equivalency, such as the equivalent diameter concept. Finally, the prediction performance of all the expressions for both cylindrical and rectangular deep drawing is analysed and compared using experimental data from the literature. The performance is evaluated in terms of the prediction error. The results have suggested that the analytical expressions involving the largest number of parameters have a superior prediction performance than the analytical expressions involving less parameters.

Optimization of Deep Drawing Processes Using Statistical Design of Experiments

1996 ◽  
Author(s):  
Dietrich Bauer ◽  
Regine Krebs
Keyword(s):  
Mathematical Model ◽  
Analysis Of Variance ◽  
Orthogonal Array ◽  
Deep Drawing ◽  
Metal Forming ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Metal Forming Process

Abstract For a deep drawing process some important controllable variables (factors) upon the maximum drawing force are analyzed to find a setting adjustment for these process factors that provides a very low force for the metal forming process. For this investigation an orthogonal array L18 with three-fold replication is used. To find the optimum of the process, the experimental results are analyzed in accordance with the robust-design-method according to Taguchi (Liesegang et. al., 1990). For this purpose, so-called Signal-to-Noise-ratios are calculated. The analysis of variance for this S/N-ratios leads to a mathematical model for the deep drawing process. This model allows to find the pressumed optimal settings of the investigated factors. In the following, a confirmation experiment is carried out by using these optimal settings. The maximum drawing force of the confirmation experiment does not correspond with the confidence interval, which was calculated by analysis of variance techniques. So the predicted optimum of the process does not lead to a metal forming process with very low deep drawing force. The comparison with a full factorial plan shows that there are interactions between the investigated factors. These interactions could not be discovered by the used orthogonal array. Thus the established mathematical model does not describe the relation between the factors and deep drawing force in accordance with the practical deep drawing conditions.

Effect of the Blank-Holding Load on the Drawing Force in the Deep-Drawing Process of Cylindrical and Square Cups

2015 ◽  
Vol 760 ◽  
pp. 379-384 ◽  
Author(s):  
Lucian Lazarescu ◽  
Ioan Nicodim ◽  
Dan Sorin Comsa ◽  
Dorel Banabic
Keyword(s):  
Aluminum Alloy ◽  
Deep Drawing ◽  
The Other ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Steel Sheets ◽  
Other Hand ◽  
Blank Holding Force

In this study, the influence of the blank-holding force (BHF) on the drawing force (DF) in the deep-drawing process of cylindrical and square cups has been investigated experimentally. For this purpose, different constant and variable BHFs have been applied to AA6016-T4 aluminum alloy and DC04 steel sheets during the forming process. It has been observed that an increased constant BHF leads to an increase of DF. On the other hand, the variable BHF approach, in which the BHF decreases in six steps throughout the punch stroke, reduces the DF.

scholarly journals Simulation of Metal Flow to Investigate the Application of Antilock Brake Mechanic System in Deep Drawing Process of Cup

2013 ◽  
Vol 789 ◽  
pp. 367-372 ◽  
Author(s):  
Susila Candra ◽  
I. Made Londen Batan ◽  
Agus Sigit Pramono ◽  
Bambang Pramujati
Keyword(s):  
Deep Drawing ◽  
Metal Flow ◽  
Low Carbon Steel ◽  
Drawing Process ◽  
Low Carbon ◽  
Drawing Force ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Cylindrical Cup

This paper presents the importance of simulation of metal flow in deep drawing process which employs an antilock brake mechanic system. Controlling the force and friction of the blank holder is imperative to assure that the sheet metal is not locked on the blank holder, and hence it flows smoothly into the die. The simulation was developed based on the material displacement, deformation and deep drawing force on flange in the radial direction, that it is controlled by blank holder with antilock brake mechanic system. The force to blank holder was applied periodically and the magnitude of force was kept constant during simulation process. In this study, the mechanical properties of the material were choses such that they equivalent to those of low carbon steel with its thickness of 0.2 mm. The diameter and the depth of the cylindrical cup-shaped product were 40 mm and 10 mm, respectively. The simulation results showed that the application of antilock brake mechanic system improves the ability to control the material flow during the drawing process, although the maximum blank holder force of 13000 N was applied. The optimum condition was found when the drawing process was performed using blank holder force of 3500 N, deep drawing force of 7000 N, friction coefficient of 0.25 and speed of punch stroke of 0.84 mm/sec. This research demonstrated that an antilock brake mechanic system can be implemented effectively to prevent cracking in deep drawing process.

scholarly journals Optimization and Mapping of the Deep Drawing Force Considering Friction Combination

2021 ◽  
Vol 11 (19) ◽  
pp. 9235
Author(s):  
Hussein Zein ◽  
Osama M. Irfan
Keyword(s):  
Deep Drawing ◽  
Plastic Anisotropy ◽  
Pattern Search ◽  
Geometrical Parameters ◽  
Drawing Process ◽  
Drawing Force ◽  
Element Analysis ◽  
Complex Deformation ◽  
Friction Coefficients ◽  
Deep Drawing Process

Deep drawing is characterized by extremely complex deformation that is influenced by process characteristics such as die and punch shapes, blank shape, blank holding force, material properties, and lubrication. The optimization of the deep drawing process is a challenging issue due to the complicated functions that define and relate the process parameters. However, the optimization is essential to enhance the productivity and the product cost in the deep drawing process. In this paper, a MATLAB toolbox (Pattern Search) was employed to minimize the maximum deep drawing force (Fd-min) at different values of the operating and the geometrical parameters. As a result, a minimum deep drawing force chart (carpet plot) was generated to show the best combination of friction coefficients at the blank contact interfaces. The extracted friction coefficients guided the selection of proper lubricants while minimizing the deep drawing force. A finite element analysis (FEA) was applied through 3D model to simulate the deep drawing process. The material modeling was implemented utilizing the ABAQUS/EXPLICIT program with plastic anisotropy. The optimization results showed that the deep drawing force and the wrinkling decrease when compared with experimental and numerical results from the literature.

Experimental Optimization of Deep Drawing Using Response Surface Methodology

2011 ◽  
Vol 121-126 ◽  
pp. 1495-1499
Author(s):  
Tsu Hsiao Chu ◽  
Kuang Hua Fuh ◽  
Wei Ching Yeh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Deep Drawing ◽  
Drawing Process ◽  
Vibration System ◽  
Drawing Force ◽  
Forming Force ◽  
Forming Process ◽  
Deep Drawing Process

A ultrasonic vibration system with ram motion of two steps is developed to optimize the formability for thin workpiece at the end of forming. The deep drawing force and forming height can be predicted in view of optimizing the values of the working variables involved in the process parameters. A response surface methodology (RSM) based on design of experiments was used in order to minimize the forming force and maximum the forming height during the deep drawing process. Associated plots are shown to be efficient for a quick choice of the optimum values of the forming process parameters.

Evaluation of Drawing Force and Thickness Distribution in the Deep-Drawing Process with Variable Blank-Holding

2015 ◽  
Vol 639 ◽  
pp. 33-40 ◽  
Author(s):  
Lucian Lazarescu ◽  
Ioan Nicodim ◽  
Dorel Banabic
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Element Model ◽  
Alloy Sheet ◽  
Wall Thickening ◽  
Drawing Process ◽  
Drawing Force ◽  
Deep Drawing Process ◽  
Blank Holding Force

In the deep drawing process, the blank-holding force (BHF) is an important process parameter affecting the energy consumption and the successful production of parts. In the present work, both experiments and finite element simulations have been conducted to investigate the influence of constant and time variable BHF on drawing force (DF) and thickness distribution in the deep drawing process of cylindrical and square cups. A finite element model was developed in the AutoForm software and validated with experiments. The developed model has been used for the simulation of deep drawing process of AA6016-T4 aluminum alloy sheet. The experimental and numerical results show that, using a variable instead of a constant BHF, the DF can be decreased in the expense of wall thickening.

scholarly journals Application of solid lubricant for enhanced frictional efficiency of deep drawing process

2021 ◽  
pp. 095440622199488
Author(s):  
RB Jivan ◽  
M Eskandarzade ◽  
SR Bewsher ◽  
M Leighton ◽  
M Mohammadpour ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Carbon Dioxide Emissions ◽  
Solid Lubricant ◽  
Reduction Rate ◽  
Experimental Tests ◽  
Friction Reduction ◽  
Process Efficiency ◽  
Drawing Process ◽  
Molybdenum Disulphide ◽  
Deep Drawing Process

Manufacturing processes are usually energy intensive, contributing to the global carbon dioxide emissions. Deep Drawing is one of the most common types of sheet metal forming processes with great potential for energy efficiency improvement. In this paper, the optimised combination of molybdenum disulphide (MoS2) and graphite is proposed as a solid lubricant to reduce the punching force and energy consumption of deep drawing process. Different mixtures of MoS2 and graphite are prepared and their tribological performance are measured using experimental tests on tribometer. In order to investigate the friction reduction rate in deep drawing process, finite element simulation of the drawing process is performed. Results show that friction reduction using proposed combination of lubricants has significant effect on punching force and would provide greater process efficiency.

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