Abstract
The developers of high aspect ratio components aim to minimize the processing stages in deep drawing processes. This study elucidates the application of microridge punches in multistage deep drawing processes. A microridge punch improves drawing performance, thereby reducing the number of stages required in deep forming processes. As an example, the original eight-stage deep forming process for a copper cylindrical cup with a high aspect ratio was analyzed by finite element simulation. Microridge punch designs were introduced in Stages 4 and 7 to replace the original punches. In addition, Stages 3 and 6 were eliminated. Finally, these changes were verified through experiments. The results showed that the microridge punches reduced the number of deep drawing stages yielding similar thickness difference percentages. Further, the numerical and experimental results demonstrated good consistency in the thickness distribution.
Highlights
The forming processes of sheet metals are advantageous for increasing the rate of production, decreasing the processing costs, improving the quality, and enhancing the yields of mechanical products and are widely applied in automotive manufacturing and various industrial products
Because the results of the analysis revealed that the microridge in the middle did not contact the blank, the middle segment of the microridge was excluded from the design to reduce manufacturing costs
Finite element analysis of copper cup drawing This study investigated the copper cylindrical cup multistage deep drawing process by using a microridge punch to reduce the number of stages
Summary
The forming processes of sheet metals are advantageous for increasing the rate of production, decreasing the processing costs, improving the quality, and enhancing the yields of mechanical products and are widely applied in automotive manufacturing and various industrial products (i.e., electronic, information, and communication products). Industries have emphasized product miniaturization, in which strength and reliability must be considered. This converts the forming processes of thin sheet metals into potential technologies for micro/meso component production technologies. The grain size of the drawing material affects the forming properties in reduced component dimensions; this is referred to as the size effect (Armstrong 1961). Several published articles have described endeavors to improve the drawability of the micro deep drawing process. Erhardt et al (1999) proposed the concept of warm microforming processes using an Nd/YAG laser to heat sheet metal workpieces locally, thereby reducing the drawing force and increasing the formability. Erhardt et al (1999) proposed the concept of warm microforming processes using an Nd/YAG laser to heat sheet metal workpieces locally, thereby reducing the drawing force and increasing the formability. Yagami et al (2007) utilized a cylindrical cup drawing experiment to investigate the influence of controlling the blank holder motion on removing wrinkles and improving drawability
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