Numerical simulation and experimental assessment for cold cylindrical deep drawing without blank-holder

Abstract

The metal forming process through plastic deformation, represented by deep drawing, is an extremely vast research field. In this article we analyse the influence of the die punch clearance, the average velocity in the active phase as well as of the lubrication on the deep drawing quality revealed by the thickness evenness on the finished product surface. For thorough research and in order to minimize the number of experimental trials, a fractional factorial design of TAGUCHI type was developed attached to an orthogonal array, thus analysing the contribution of the three aforementioned parameters to the quality of cylindrical deep drawing without a blank holder. In order to compare the experimental results, a conceptual 3D model of the system punch-blank-die was made, which respects entirely the geometry of the active elements and of the blank, but schematizes/approximates the material properties of the blank. Thus, using these simulations, we can investigate the variation of the deformation parameters throughout the drawing process: from the initial blank form to the final drawn part. The numerical simulation of the drawing of cylindrical cups was made using the ANSYS V14 program, the Explicit Dynamic module. Using the signal-to-noise ratio suggested by TAGUCHI, we determined the influence of each of the three parameters under study on deep drawing quality, as well as their optimal values.