Experimental study and Numerical simulation of stress concentration in deep drawing process without blank holder

Document Type : Research Paper

Authors

1 Mechanical Engineering Dept., Faculty of Engineering, Beni-Suif university, Ben-Suef, Egypt.

2 Mechanical Engineering Dept., Faculty of Engineering, South Valley University, Qena, Egypt

3 Mechanical Design and production , Facutly of Engineering ,Assuit University, Assiut, Egypt.

4 Production Technology Dept., Faculty of Technology and Education, Beni-Suef University, beni-Suef, Egypt

Abstract

Deep drawing without blank holder is an important process for producing circular cups which used in many applications. In this process, the blank is subjected to various loads and stresses concentrations which can lead to cup failure. This research presents a theoretical and experimental study on the effects of stresses concentrations in the deep drawing without blank holder. A simulation model was constructed the Dynamic Simulation Software - DEFORM software - to study the appropriate values for the variables. Practical experiments were conducted on universal testing machine configured for the process. Aluminum blanks were used as specimens with a thickness of 3 mm and various diameters. The process is carried out by placing the blank on the die and balancing it, then moving the punch downward to complete drawing process. During process, the specimen is subjected to loads pulling it downward. To avoid this, several suggestions were made to disperse the stresses and reduce the impact of stress concentration. The experiments were conducted at a speed of 9 mm per minute. For all experiments, the forming loads was measured during process. The results showed that avoiding stress concentration in the deep drawing process without blank holder had a significant effect in reducing the forming forces, minimizing the tearing of the samples, and improving the mechanical properties of the cups. The drawing ratio reached 2.46, which is a high percentage compared to the traditional condition, also there was a convergence between the theoretical, simulated, and experimental results

Keywords

Main Subjects

References

[1]   Kumar, R.U., Effect of blank radius on radial stresses in hydroforming deep drawing process. International Journal of Applied Research in Mechanical Engineering, 2012: p. 231-236.  DOI: 10.47893/IJARME.2012.1042.
[2]   Reddy, P.V., et al., Effect of Geometries of Die/Blank Holder and Punch Radii in Angular Deep-Drawing Dies on DP Steel Formability. Applied Mechanics and Materials, 2015. 813-814: p. 269-273. DOI: 10.4028/www.scientific.net/AMM.813-814.269.
[3]   Müller, M., et al., Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries. Advances in Industrial and Manufacturing Engineering, 2024. 8: p. 100136. https://doi.org/10.1016/j.aime.2024.100136.
[4]   Wang, H., et al., Evaluation of the formability of AA2198-T3 Al-Li alloy in warm sheet hydroforming. The International Journal of Advanced Manufacturing Technology, 2022. 118(1): p. 405-416. https://doi.org/10.1007/s00170-021-07961-z.
[5]   Morovvati, M.R., A. Fatemi, and M. Sadighi, Experimental and finite element investigation on wrinkling of circular single layer and two-layer sheet metals in deep drawing process. The International Journal of Advanced Manufacturing Technology, 2011. 54(1): p. 113-121. https://doi.org/10.1007/s00170-010-2931-9.
[6]   Özbek, R. and O. Gül, Effect Of Radius On Deep Drawing Stress Analysis. International Conference on Pioneer and Innovative Studies, 2023. 1: p. 374-378. DOI: 10.59287/icpis.859.
[7]   Kapil Dudhatra, S.G., Maulik Khunt, Tushar Kaneriya, Jasmin Hirpara, EFFECT OF VARIOUS PARAMETER ON WRINKLING IN DEEP  DRAWING CYLINDRICAL CUPS WITH DIFFERENT MATERIAL. International Journal For Technological Research In Engineering 2018. 5(8): p. 2566-2572. IJETT - Effect of Various Parameters on the Wrinkling In Deep Drawing Cylindrical Cups (ijettjournal.org).
[8]   Phanitwong, W. and S. Thipprakmas, Multi Draw Radius Die Design for Increases in Limiting Drawing Ratio. Metals, 2020. 10(7): p. 870.  https://doi.org/10.3390/met10070870.
[9]   Özek, C. and M. Bal, The effect of die/blank holder and punch radiuses on limit drawing ratio in angular deep-drawing dies. The International Journal of Advanced Manufacturing Technology, 2009. 40(11): p. 1077-1083. https://doi.org/10.1007/s00170-008-1435-3.
[10]  Trieu, Q.-H., et al., A Study on Yield Criteria Influence on Anisotropic Behavior and Fracture Prediction in Deep Drawing SECC Steel Cylindrical Cups. Materials, 2024. 17(12): p. 2872.  https://doi.org/10.3390/ma17122872.
[11]  Shewakh, W., M.A. Hassan, and I. Hassab-Allah, Square-Cup Deep Drawing of Relatively Thick Sheet Metals through a Conical Die without Blankholder. International Journal of Materials Forming and Machining Processes, 2015. 2: p. 31-46. DOI: 10.4018/IJMFMP.2015070103.
[12]  The-Thanh, L., et al., A study on a deep-drawing process with two shaping states for a fuel-filter cup using combined simulation and experiment. Advances in Mechanical Engineering, 2019. 11(8): p. 1687814019872674. https://doi.org/10.1177/168781401987267.
[13]  Amini, A., et al., Hydro-mechanical deep drawing of conical components: Wrinkling behavior and process enhancement. Journal of Engineering Research, 2024. https://doi.org/10.1016/j.jer.2024.04.005.
[14]  Hwang, Y.-M., et al., Formability Prediction Using Machine Learning Combined with Process Design for High-Drawing-Ratio Aluminum Alloy Cups. Materials, 2024. 17(16): p. 3991. https://doi.org/10.3390/ma17163991.
[15]  Abdel-Magied, R., et al., An Investigation into Deep Drawing Process without Blank Holder. 2020. http://sersc.org/journals/index.php/IJAST/article/view/4317.
[16]  Sun, W., W. Liu, and S. Yuan, Suppressing wrinkles in thin-walled dome parts: A novel deep drawing method with active stress control. Journal of Materials Processing Technology, 2024. 324: p. 118249. https://doi.org/10.1016/j.jmatprotec.2023.118249.
[17]  Gavas, M. and M. Izciler, Design and application of blank holder system with spiral spring in deep drawing of square cups. Journal of Materials Processing Technology, 2006. 171(2): p. 274-282. https://doi.org/10.1016/j.jmatprotec.2005.06.082.
[18]  Fan, X., X. Chen, and S. Yuan, Novel forming process for aluminum alloy thin shells at ultra-low temperature gradient. International Journal of Machine Tools and Manufacture, 2023. 185: p. 103992. https://doi.org/10.1016/j.ijmachtools.2022.103992.
[19]  Brabie, G., B. Chirita, and A. Albut, Minimization of sheet thickness variation and other defects of mini drawn parts using a blank holder plate made from concentric rings. Precision Engineering, 2015. 42: p. 311-320. https://doi.org/10.1016/j.precisioneng.2015.03.011.
[20]  Lee, S., et al., Gaussian process regression-driven deep drawing blank design method. International Journal of Mechanical Sciences, 2024. 265: p. 108898. https://doi.org/10.1016/j.ijmecsci.2023.108898.
[21]           Heshmat, Mahmoud, and Mohamed Adel. "Investigating the effect of hot air polishing parameters on surface roughness of fused deposition modeling PLA products: ANOVA and regression analysis." Progress in Additive Manufacturing 6.4 (2021): 679-687
[22]           Heshmat, M., & Abdelrhman, Y. (2020). ANOVA and regression model of slurry erosion parameters of a polymeric spray paint film. International Journal of Materials Engineering Innovation, 11(3), 198-211.‏
[23]           Heshmat, M., Maher, I., & Abdelrhman, Y. (2023). Surface roughness prediction of polylactic acid (PLA) products manufactured by 3D printing and post processed using a slurry impact technique: ANFIS-based modeling. Progress in Additive Manufacturing, 8(2), 87-98.‏
[24]           Astakhov, V. P. (2012). Design of experiment methods in manufacturing: Basics and practical applications. In Statistical and computational techniques in manufacturing (pp. 1-54). Berlin, Heidelberg: Springer Berlin Heidelberg.‏
[25]           Abdelaal, O., Heshmat, M., & Abdelrhman, Y. (2020). Experimental investigation on the effect of water-silica slurry impacts on 3D-Printed polylactic acid. Tribology International, 151, 106410.‏

Files

Share

How to cite

Statistics