Abstract
In this article, a deep-drawing process using a double-action hydraulic press is examined for its ability to machine the shaping deformation of a fuel-filter cup made from SPCC steel. Many researchers have studied the geometric, physical, and technological parameters of the deep-drawing process. However, most of those studies ignored the optimization parameters of the two shaping deformation states to ensure uniformity of thickness and the disappearance of wrinkling and tearing during machining. In this study, geometric and technological parameters (e.g. blank-holder force, die-shoulder radius, and radial clearance between punch and die) are optimized in both states. The deep-drawing process for a fuel-filter cup is simulated using ABAQUS software, and optimal parameters are determined by applying the Taguchi orthogonal array computation and combining it with an analysis of variance method. The numerical results are then verified with corresponding experiments. The obtained numerical and experimental results show that the die-shoulder radius is one of the most influential parameters affecting the shaping of the cup during the deep-drawing process. Moreover, the influences of technological parameters on the formability of sheet metal are finally analyzed and selected for designing and improving deep-drawing molds.
Highlights
Fuel-filter cups on cars and trucks are used to remove impurities from oil before returning it to the engine for lubrication and cooling
finite element method (FEM) and experimental models are constructed for the deep-drawing process of a fuel-filter cup
The deep-drawing process of the fuel-filter cup was performed on the double-action hydraulic press at the maximum load capacity of 50 tons
Summary
Fuel-filter cups on cars and trucks are used to remove impurities from oil before returning it to the engine for lubrication and cooling. Raju et al.[2] researched the influence of technological and geometric parameters of the deep-drawing process for cups made of sheet material AA6061. FEM and experimental models are constructed for the deep-drawing process of a fuel-filter cup. The deep-drawing process of shaping the fuel-filter cup is simulated with ABAQUS software.[16] The 3D FEM model for the deep-drawing process is shown, wherein the punch is fixed, and a blank holder and die are moved in the vertical direction to achieve the size of the shaped cup via two deformation states. To design fuel-filter cup molds, geometrical parameters should be recognized, as shown, where rd is the die-shoulder radius, rp is the punch-nose radius, t is the blank thickness, and wc is the radial clearance between punch and die. The height of the cup at the nth drawing step is calculated as equation (14)
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