Abstract
Earing is a common defect that occurs in deep drawing process due to non-uniform material properties within the plane of the sheet that is planar anisotropy. In this study, efforts were made to study the earing problem in deep drawing of cylindrical cups by finite element modeling using HYPERWORKS6.10. Interstitial Free (IF) steel sheet of 1.0 mm thickness has been considered as it has wide application in fabricating critical automobile components. Mechanical properties of IF steel along with tool design parameters were incorporated in the finite element modeling of deep drawing process.Significant earing was observed at rolling and transverse direction in the deformed cup from a circular blank. The cup heights were measured at several points with respect to the rolling direction of the sheet. To minimize earing, flow of material was observed at various steps during the simulation and accordingly initial blank shape had been modified. Modified blanks showed significant reduction in earing and improvement in thickness distribution in simulation.
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