Experimental and Theoretical Analysis to Produce Pentagonal Cup in Deep Drawing Process

Abstract

The manufacturing industry heavily relies on deep drawing due to its remarkable ability to produce intricate symmetrical and asymmetrical shapes with accuracy and efficiency. This research aimed to create a deep drawing tool capable of producing a pentagonal cup measuring 41mm in diameter and 30mm in height. This was achieved by conducting numerical simulations and experimental tests using two different methods. The first method involved converting an 80mm diameter circular blank into a pentagonal cup through a drawing operation, while the second method involved redrawing a cylindrical cup into a pentagonal shape. The study also analyzed the impact of these methods on the drawing load, stress/strain distributions, and thickness distributions. The finite element method software, ANSYS 20, was employed for numerical simulations. The results showed that the first method had a significantly higher punch load than the second method. However, the pentagonal cup produced using the first method had a greater thickness reduction towards the cup wall curvature compared to those produced using the second method. Therefore, the second method was considered ideal for manufacturing a pentagonal cup because it resulted in a lower degree of thinning at the cup curvature and a more uniform distribution of thickness, stress, and strain. In conclusion, this research highlights the importance of deep drawing in the manufacturing industry and emphasizes the need to choose the appropriate forming method to achieve optimal results.