Abstract
Wrinkling of beverage cans is one of the problems faced by can manufacturers and aluminum suppliers. The bottom of an aluminum can is wrinkled by compression during the forming process. In this study, to predict the occurrence of wrinkles during the redrawing process of AA3104 (t = 0.265 mm), which is the material used to fabricate aluminum cans, the classical plasticity J2 deformation theory (J2D) and flow theory (J2F) were considered. J2F considers only the deformation perpendicular to the yield locus, whereas J2D considers the deformation perpendicular to the yield locus and that tangential to the yield locus. Wrinkles are predicted using finite element (FE) analyses based on J2D and J2F, and the results are compared. J2F could not predict the number and amplitude of wrinkles. By contrast, the wrinkles predicted using J2D exhibited good agreement with sample data obtained for a real can. To find the difference between the results obtained using J2F and J2D, evolutions of stress path in a wrinkled element are compared. It was confirmed that compressive stress is more dominant in the J2D case than in the J2F case. Moreover, the measured effective strain of the element is small, under 0.04. In conclusion, J2D is more suitable for predicting the wrinkling behavior of aluminum cans than J2F. In addition, ANOVA and ANOM analysis are performed to evaluate the influence of the design parameters, namely friction coefficient, thickness, and outer profile angle, and the parameters are optimized to reduce wrinkles by combining the Taguchi method with FE simulation based on the J2D theory.
Highlights
Wrinkling problem is encountered in the drawing of automotive parts and beverage cans for over 40 years
We considered beverage cans because more than 40 wrinkles of small magnitude are created in the fabrication of this product
Storen and Rice [31] proposed the J2 deformation theory based on the necking phenomenon, which is a local plastic deformation caused by the instability of plane stresses
Summary
Wrinkling problem is encountered in the drawing of automotive parts and beverage cans for over 40 years. Predicted the wrinkles formed after deep drawing They considered plastic behaviors by using the geometry,the process parameters, and clearance are selected. [19] behaviors predicted by theusing wrinkles predicted wrinkles formed after deep drawing They considered the hardening function and the anisotropic yield function to describe material properties accurately. They considered plastic behaviors using the hardening functionKim and hardening function and the anisotropic yield function to describeby material properties accurately. Dick and Yoon [29] studied the effects of the hardening function and anisotropic yield function from the viewpoint of considering the properties of anisotropic material behavior They performed an FE simulation by using the flow theory in conjunction with Barlat’s Yld2000-2d anisotropic yield function [30], which provides a good description of anisotropic material behavior. The simulation results obtained using the optimized variables indicated reduced wrinkle formation
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