Finite element simulation analysis of laminated sheets in deep drawing process using response surface method

Abstract

In the present study, deep drawing process of brass-steel laminated sheets was investigated from the required forming load and thickness reductions points of view. Firstly, the process was simulated using finite element method (FEM) and then was verified using experimental data. For investigation of different process parameters since the implementation of fully experimental or simulation design is impossible, the design of experiments using response surface method (RSM) was carried out. The main effect of six considered parameters on required forming load and thickness reductions was studied and regression models for estimating the forming load and thickness reductions were represented in high reliability. The results showed that all terms of presented regression model were effective on response values. Also, the results of analysis of variance (ANOVA) illustrated that blank radius, steel friction coefficient, and punch nose radius with 53, 28, and 12% of contribution, respectively, were the most effective parameters on required forming load. It was illuminated that brass friction coefficient does not affect the forming load according to the obtained results. Also, according to the results, steel friction coefficient was the most important parameters on thickness reductions of both sheets with 41 and 39% contributions, respectively.