Experimental and numerical investigations of Al 1100 cup using conical die without blank holder

Abstract

In sheet metal forming processes, the wrinkle phenomenon has been one of the main limiting failure factors. Both numerically and experimentally investigations were done using conical cup test method for wrinkling phenomena. This research work aim is to drawing a flat-bottom cylindrical cup from Al 1100 sheet material, with the effect of drawing parameters, including blank shape, blank thickness, load, and dry lubrication, employing both numerical and experimental methods. Simulation results were obtained using ANSYS 19.2 software, while experimental data were acquired through a universal testing machine. The optimization of process parameters led to the formation of a cylindrical cup with a flat bottom and no defects like thinning or wrinkling. This parametric research contributes to the accurate prediction of the final geometry of the sheet blank and the distribution of stresses, crucial for the forming process and the production of high-quality products. The results show that a die angle of 20° and an optimized punch speed of 3.5 mm/sec give the wrinkle-free cup with high compressive strength.