Numerical Simulation of Aluminum and Brass Material Cups in Deep Drawing Process

Abstract

In the deep drawing process, blank material is converted into the desired shapes by a punch. In this research paper, different material (Aluminium and Brass materials) cylindrical cup has been developed without blank-holder. Effects of die and punch geometry, including die and punch fillet radius, on limiting drawing ratio (LDR.), drawing load with respect to punch stroke and stress-strain of the cup wall have been investigated numerically for optimal process design. A commercial finite element simulation package, ANSYS 14.0, is used to investigate the developed setup in order to determine the optimum limiting drawing ratio. A numerical model is built accordingly with a half cone angle of 18°. Aluminium alloy AA1200 and brass CuZn33 sheets are used in the F.E. analysis. The effects of the original blank thickness (t=1.5, 2, and 3.0mm) and the orientation of the blank rolling direction (0°, 45°, and 90°) to the punch side on the various limiting drawing ratio (LDR) and punch load are numerically investigated. The present process successfully produces cylindrical cups with drawing ratios of 2.53, 2.64 and 2.86 aluminum and brass. And also, by the help this latest process, one die will produce different shapes only different radius punch were used. Comparison between numerical results and the available published work showed that the required punch pressure in the latest process and defect free product are produced while the LDR is increased.