Numerical and experimental analyzes of forming parameters of low carbon steel

Abstract

Understanding sheet metal forming presses are important to reduce manufacturing costs. Thus, the best method of finding the optimum values of processing is by studying the effect of forming parameters on the behavior of formability, friction, and die radius. In this work, the deep drawing process of a low-carbon steel cup was studied and the significance of two important process parameters are investigated which are the friction coefficient and the radius of the die. The finite element method program, ANSYS, is used to study the effect of these parameters on forming load in the deep drawing process. The three ​​levels of friction coefficient are considered which are 0.08, 0.00, and 0.15, and three die shoulder radius of 4, 6, and 8 mm. The results show that the predicted behavior of the punch load coincided well with both experimental and practical behaviors and the confidence is exceeding 94%. The wrinkling defect is happening when using a high die radius, Rd=8mm although the punch load is low due to the increase in the surface area on the edge of the die.