Abstract
In this paper a new modified processing route for deep drawing has been proposed for producing long cylindrical cups from 12 mm thick circular blanks of Aluminium (Al)-killed AISI 1010 steel, without blank-holder. In this modified route, flat blanks were fabricated to a preformed shape by stamping operation and then followed by multistage drawing processes to increase depth of the cups. Wall ironing was also purposefully included in each draw step with deep drawing processes to reduce wall thickness and earing tendency on cup edges. Thus, evolution of wall thickness distribution, drawability and ironability parameters, punch force history, microstructures and strain distribution profiles on outer cup surfaces were obtained as effects of interaction between processes, tools and material in the investigation. The overall draw stages showed: LDR 2.06; overall draw reduction >50% with a drawing efficiency ~72%; LIR 3.55; overall ironing reduction >70% with an ironing efficiency ~68%, which were achieved in the experimental works.
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