Abstract
In this paper a new modified processing route has been proposed for producing long cylindrical cups from 12 mm thick circular blanks of AISI 1020 steel (Aluminium (Al) -killed). In this route, flat blanks were made to preformed shape by stamping operation, followed by multistage deep drawing processes(without blank-holder and with inter-stage stress relief annealing) to increase cup depth. Wall ironing was also purposefully included in each draw step to reduce wall thickness and earing tendency on cup edges. Thus, evolution of wall thickness distribution, Drawability and Ironability, punch force history, and strain distribution profiles on outer cup surfaces were obtained as the effects of interaction between processes, tools and material. The overall draw stages showed: LDR 2.06; overall draw reduction >50% with a drawing efficiency ~72%; LIR 3.55; overall ironing reduction >70% with an ironing efficiency ~68%, which were achieved in the experimental works.
Highlights
Sheet metal forming is one of the most widely used manufacturing processes for the fabrication of a wide range of products in many industries
In order to maintain the relative thickness, it needs to cut a blank of larger diameter that associated with processing difficulties like, needs of larger die – punches, increased draw forces demands a greater press stroke, requires more numbers of draw steps to accommodate draw ratio and arousal of various forming defects etc
Increase in blank thickness raises the level of formability limit diagram (FLD)[1,2,3], enhances limit draw ratio (LDR) value[2, 4], reduces tendency of wrinkling[2, 5] and earing effects on cups[6], which can
Summary
Sheet metal forming is one of the most widely used manufacturing processes for the fabrication of a wide range of products in many industries. Deep drawing is one of the extensively used sheet metal forming processes in the industries to have mass production of cup shaped components in a very short time. In order to maintain the relative thickness, it needs to cut a blank of larger diameter that associated with processing difficulties like, needs of larger die – punches, increased draw forces demands a greater press stroke, requires more numbers of draw steps to accommodate draw ratio and arousal of various forming defects etc. Unlike conventional sheet metal work, Materials Research a thicker blank, i.e.12 mm thick - 60 mm diameter circular blanks were used for producing long cylindrical cups by a modified processing route consisted with pre-forming of blanks followed by multistage deep drawing without blank-holder. It is tried to create a real time data bank for filling up the knowledge gap
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