Abstract
This study investigates the thickness variation behavior of deep drawing conical products under the effect of different forming parameters such as die wall inclination angle, punch velocity, sheet thickness, and sheet metal type. Two types of sheet metal were used, low carbon (AISI 1008) and galvanized steel sheets, of 110 mm diameters circular blanks at 0.9 and 1.2mm thickness formed by tooling set (punch, die, and blank holder). The conical dies inclination angles were at 70ᵒ, 72ᵒ, and 74ᵒ where, the punch velocity was 100, 150, and 200 mm/min. Numerical simulation was conducted using ABAQUS 6.14 where a dynamic explicit solver was used to perform forming of conical products. The results show that maximum thinning occurs at punch nose radius region and maximum thickening in sidewall region and thinning are increased with the increasing of die sidewall angle and sheet thickness. In regard to sheet type, the Lankford coefficients r-value shows a great role in thinning behavior with respect to rolling (r-values direction). The results have shown a good agreement between experimental and numerical work with a maximum discrepancy of 5%.
Highlights
The tooling set included a punch that used to push the circular blank to flow into the gap confined between the punch and die
To demonstrate the effect of r- value, low carbon steel material that has rvalues of r0, r45, and r90 are 0.37583, 0.29023, and 0.5343 respectively with 70o die wall angle was taken as an example from this study during the deep-drawing process
1) The results show good agreement between experimental and numerical work with a maximum discrepancy of 5%
Summary
The tooling set included a punch that used to push the circular blank to flow into the gap confined between the punch and die. Spring back, thinning and thickness distribution of sheet metal in deep drawing operation are predicted by Zein et al [6]. Padmanabhan [16] study the influence of three of the most important deep drawing parameters named holding force, friction coefficient, and die radius on the thickness distribution of the product. The thickness variation behavior of deep drawing conical steel products is investigated under the effect of different forming parameters such as die wall inclination angle, punch velocity, sheet thickness, and sheet metal type. This is achieved experimentally and numerically using the finite element technique
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