Optimal Blank Shape Prediction Considering Sheet Thickness Variation for Multistage Deep Drawing

2015 ◽  
Author(s):  
Anupam Agrawal ◽  
N. Venkata Reddy ◽  
P. M. Dixit
Keyword(s):  
Velocity Field ◽  
Deep Drawing ◽  
Sheet Thickness ◽  
Thickness Variation ◽  
Normal Velocity ◽  
Shape Prediction ◽  
Input Material ◽  
Blank Shape ◽  
Automobile Components ◽  
Volume Constancy

Deep drawing is one of the very old and widely practiced processes in the sheet metal industries for producing beverage cans and automobile components. Many of the deep drawn components need multiple draws to achieve the required dimensions, because often it is not possible to obtain the desired reduction in the first draw. Among several defects that occur during the process, earing is one of the prominent and common defect. In the present work, analysis has been carried out by dividing the total deformation region into several zones. Analysis of each zone is carried out by proposing kinematically admissible velocity field, i.e. the velocity field satisfying the condition of normal velocity continuity and volume constancy. The input material (already drawn cup) for redrawing is pre-strained from the previous stage drawing operation and this has been considered while carrying out the analysis. Thickness and punch load predictions are validated by comparing them with the published results and are found to be in good agreement. The optimal blank shape, that will result in earing free cup after the final drawing operation, has been determined. For the prediction of optimal blank shape for multistage deep drawing, addition-subtraction scheme has been developed and successfully implemented; the modification of the initial blank is done after each stage of drawing. The optimal blank shape obtained has been tested, using simulation, to draw the cup and it yields the final cup height with percentage earing less than 1%. However, in a few cases, three or four iterations for the modification of blank may be required, to bring the percentage earing within the specified limit.

Minimization of Sheet Thickness Variation and other Defects of the Mini Drawn Parts Using the Genetic Algorithms Method

2015 ◽  
Vol 809-810 ◽  
pp. 241-246
Author(s):  
Gheorghe Brabie ◽  
Bogdan Chirita
Keyword(s):  
Genetic Algorithms ◽  
Deep Drawing ◽  
Sheet Thickness ◽  
Thickness Variation ◽  
Sheet Metals ◽  
Part Geometry ◽  
Diameter Variation ◽  
Optimal Values ◽  
Working Parameters ◽  
Major Defect

Thickness variation is a major defect of the drawn parts made from sheet metals that influences the intensity of part defects. In the case of mini deep drawing, the sheet thickness variation along parts profile has the following effects on the drawn part geometry: increases the non-uniformity of the part diameter variation; influences the values of springback parameters (part edge radius deviations and angle of wall inclination); influences the intensity of wrinkling; causes the part cracking and fracture. Hence, the main objective in the mini scale deep drawing processes must be to increase the drawn part accuracy by minimizing the thickness variation in the drawn parts, i.e. to minimize the values of thinning and thickening. The present paper analyses the results of investigations made to minimize the thickness variation and hence to increase the accuracy of the mini drawn parts by determining the optimal values of the working parameters from the application of the Genetic Algorithms method.

scholarly journals Investigation of Thickness Distribution Variation in Deep Drawing of Conical Steel Products

2021 ◽  
Vol 39 (4A) ◽  
pp. 586-598
Author(s):  
Muhsin J. Jweeg ◽  
Adnan I. Mohammed ◽  
Mohammed S. Jabbar
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Sheet Thickness ◽  
Galvanized Steel ◽  
Thickness Variation ◽  
Low Carbon ◽  
Nose Radius ◽  
Numerical Work ◽  
Punch Velocity

This study investigates the thickness variation behavior of deep drawing conical products under the effect of different forming parameters such as die wall inclination angle, punch velocity, sheet thickness, and sheet metal type. Two types of sheet metal were used, low carbon (AISI 1008) and galvanized steel sheets, of 110 mm diameters circular blanks at 0.9 and 1.2mm thickness formed by tooling set (punch, die, and blank holder). The conical dies inclination angles were at 70ᵒ, 72ᵒ, and 74ᵒ where, the punch velocity was 100, 150, and 200 mm/min. Numerical simulation was conducted using ABAQUS 6.14 where a dynamic explicit solver was used to perform forming of conical products. The results show that maximum thinning occurs at punch nose radius region and maximum thickening in sidewall region and thinning are increased with the increasing of die sidewall angle and sheet thickness. In regard to sheet type, the Lankford coefficients r-value shows a great role in thinning behavior with respect to rolling (r-values direction). The results have shown a good agreement between experimental and numerical work with a maximum discrepancy of 5%.

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

Controlling the Thickness Uniformity in Equal Channel Angular Rolling (ECAR)

2007 ◽  
Vol 539-543 ◽  
pp. 2872-2877 ◽  
Author(s):  
Young Hoon Chung ◽  
Jong Woo Park ◽  
Kyong Hwan Lee
Keyword(s):  
Shear Strain ◽  
Shear Deformation ◽  
Control Mechanism ◽  
Sheet Thickness ◽  
Surface Friction ◽  
Metal Sheet ◽  
Thickness Variation ◽  
Thickness Control ◽  
Thickness Uniformity ◽  
Elastic Unit

As the surface friction between feeding rolls and metal sheet generates the feeding power of ECAR, the generated feeding power is low, and the friction between the metal sheet and ECAR die should be minimized. However, for obtaining a large shear deformation by ECAR, the metal sheet should be tightly contacted with the wall of ECAR die. In this condition, the thickness of the metal sheet is continuously increased during ECAR. A new ECAR apparatus is developed for maximizing the shear deformation and obtaining sheet thickness uniformity, and succeeding continuous ECAR with such a limited feeding power. By controlling the outlet gap of the ECAR die with elastic unit, the thickness of the metal sheet is kept uniform. Detailed thickness control mechanism during the new ECAR process is analyzed. A sheet of Al 6063 alloy that is 1-pass deformed with the new ECAR apparatus shows below ±0.037 mm of thickness variation and 0.61 of shear strain.

Analysis of the Strain Distribution and Texture Measurements in Asymmetric Rolling (AR) and Asymmetric Accumulative Roll Bonding (AARB)

2021 ◽  
Vol 1016 ◽  
pp. 715-724
Author(s):  
Renan P. Godoi ◽  
Bianca D. Zanquetta ◽  
José Benaque Rubert ◽  
Raul E. Bolmaro ◽  
Martina C. Avalos ◽  
...  
Keyword(s):  
Accumulative Roll Bonding ◽  
Sheet Thickness ◽  
Thickness Reduction ◽  
Thickness Variation ◽  
Asymmetric Rolling ◽  
Roll Bonding ◽  
Bonding Condition ◽  
Shear Component ◽  
Strong Shear ◽  
Metallic Composites

Severe plastic deformation (SPD) with strong shear component is required to promote both grain refinement and texture randomization. When Asymmetric rolling (AR) is applied as asymmetric accumulative roll bonding (AARB), it enables the production of architectured microstructures and metallic composites. Finite element (FE) simulations of AR and AARB were employed to understand the influence of pass thickness reduction (PTR) on the through thickness variation of the velocity gradient. The influence of the PTR up to a total thickness reduction of 50% and the effect of a single 50% reduction step in a bi-layer bonding condition was analyzed. The influence of these process parameters on the strain and rigid body rotation components was compared with the experimental data obtained on an AA1050 aluminum. A better shear to compression ratio across the sheet thickness is achieved by PTRs lower than 30%; at a PTR of 50% the texture is dominated by the frictional shear generated at the roll-sheet interface and the process has a stronger compressive character. This indicates that simple ARB followed by AR with smaller PTRs should generate a better shear distribution than AARB alone.

Optimization of the geometrical parameters for elevated temperature hydro-mechanical deep drawing process of 2024 aluminum alloy

2020 ◽  
pp. 095440892094936
Author(s):  
S Yaghoubi ◽  
F Fereshteh-Saniee
Keyword(s):  
Aluminum Alloy ◽  
Elevated Temperature ◽  
Objective Function ◽  
Deep Drawing ◽  
Sheet Thickness ◽  
Bees Algorithm ◽  
Group Method ◽  
Geometrical Parameters ◽  
2024 Aluminum Alloy ◽  
Experimental Findings

This research is concerned with the effects of the geometrical parameters of the die in elevated temperature Hydro-Mechanical Deep Drawing (HMDD) process of 2024 aluminum alloy. A Group Method of Data Handling (GMDH) process was used to train a neural network in order to study the process behavior. Based on the maximum reduction in sheet thickness and the uniformity of the final product, an objective function was constructed. The Bees Algorithm (BA) was used to achieve the optimal values for process variables. To verify the simulation results, they were compared with the experimental findings gained via this research and an appropriate correlation was observed between these results. This comparison showed that, by optimization of the geometrical parameters of the process, the value of the combined objective function was the best one compared with all of the cases tried in the present investigation.

Blank Shape Optimization in Deep Drawing with Combined Restraint

2013 ◽  
Vol 371 ◽  
pp. 178-182
Author(s):  
Viorel Paunoiu ◽  
Virgil Teodor
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Degree Of Deformation ◽  
Initial Blank ◽  
Mathematical Relation ◽  
Blank Shape Optimization ◽  
Cylindrical Parts ◽  
Blank Shape ◽  
High Degree

One of the methods for increasing the degree of deformation in the deep drawing of the cylindrical parts is the method with the combined restraint. In this process, due to the high degree of deformation, the earing is pronounced and affects the quality of the final part. The paper focuses in optimization the blank shape in this process applying a method which combines a mathematical relation with the results of the numerical simulation. The mathematical relation connects the radii of the initial blank at the different angles with the sizes of the part heights at different angles. The numerical simulation using FEM was used for the heights determination at the main anisotropy directions considering different initial blank dimensions. An experimental work was done for certify the numerical results. The results confirmed that the optimization of the blank shape in deep drawing with the combined restraint is a key for improving the deformation process, for reduction the earing and for minimizing the material consumption.

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