Abstract
In deep drawing, a low blank holder force (BHF) can cause wrinkling, while a high BHF can lead to tearing. In this study, a variable blank holder force (VBHF) approach to deep drawing is employed, and a simple closed-loop type algorithm is developed for the VBHF trajectory. The proposed algorithm is divided into two phases. The objective of the first phase is to check wrinkling and tearing. In this phase, a low BHF is used as the initial BHF, which is then increased to prevent wrinkling while controlling tearing. This phase of the algorithm is terminated when tearing occurs. In numerical simulation, the distance between the die and the blank holder is used to measure wrinkling, and the minimum thickness of the blank is used to determine the tearing. In the second phase of the algorithm, the deviations in thickness of the part are iteratively examined, without neglecting the occurrence of wrinkling. One of the advantages of using VBHF instead of constant BHF is that it reduces the forming energy. The validity of the proposed algorithm is examined comparing numerical simulation and experimental results. Finally, the proposed algorithm is also applied to obtain the segmented VBHF trajectory.
Highlights
Computer Aided Engineering (CAE) is widely used in industry
The variable blank holder force (VBHF) trajectory was obtained through a numerical simulation, and the experiment was conducted based on this VBHF trajectory
A simple closed-loop type algorithm for the VBHF trajectory was developed, and it was applied to a square cup deep drawing
Summary
Computer Aided Engineering (CAE) is widely used in industry. Physical phenomena can be understood using CAE. In order to avoid wrinkling and tearing, local quantity such as the distance between the die and blank holder was widely employed in the numerical simulation. These researches did not consider any global quantity evaluated for the blank throughout the forming process. In RSM approaches only a few strokesteps are taken as the design variables These result in a rough VBHF trajectory in comparison with the one obtained with closed-loop type algorithms. The proposed algorithm is applied to determine the variable blank holder force trajectory for a segmented binder. The proposed algorithm is applied to determine the VBHF trajectory for a segmented binder
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