Experimental and numerical analysis of aluminium alloy cylindrical cup using novel deep drawing technique

Abstract

ABSTRACT In the traditional deep drawing process, a blank holder is required to press the blank over the die to prevent wrinkling and to control the material flow into the die cavity. But, this important tool responsible for fracture on the sheet and the optimisation of blank holder pressure is very critical. This present study introduces a new technique for the deep drawing process of cylindrical cups through a conical die without a blank holder. In this new technique, cylindrical cups are produced by pushing a circular blank using a flat-headed cylindrical punch through a conical die with a cylindrical throat in a single punch stroke. A 3-D parametric FE model was built using the commercial FE package ANSYS/APDL-19. A die with a half cone angle of 18° has shown the best drawability for the new technique. A flat-headed punch was used for forming of AA8011 & AA1200 with 1 to 2 mm initial thicknesses and diameters varies from 45 to 65 mm in experimental analysis. 100-ton hydraulic press used for deep drawing setup. Finite element model results showed good agreement with experimental results. Experimentally, a cylindrical cup with a LDR of 2.5 has been successfully achieved.