Experimental investigation of forming parameters for square cup deep drawing process

Abstract

Abstract Manufacturing a defect free drawn part is always challenging task. This paper presents numerical analysis and experimental validation of deep drawing process in order to avoid thinning and wrinkles. Numerical and experimental approaches are used to analyze the effect of different drawing parameters such as blank shape, blank thickness, load, dry/wet lubrication on square cup drawing process using extra deep drawn steel (EDD) sheet material. Results of simulation through computer aided engineering (CAE) software are validated through experimentation. Formability analysis on the laser engraved circular grids formed on the blank surface is carried out using forming limit diagram (FLD). The optimized process parameters helped to form a square cup without any defects such as thinning, wrinkling, etc. Experimental and formability analysis showed that for considered process parameters, formability of material having a blank thickness of 2 mm is better as compared to a blank thickness of 1 mm and 0.8 mm, for load of 100 kN with dry lubrication. This work highlights the significance of forming limit diagram technique in strengthening numerical and experimental investigation of deep drawing process. In overall, this parametric study leads to prediction of final geometry of sheet blank accurately and distribution of strain and stresses, for the development of quality product through forming process.