Redrawing analysis of aluminum–stainless-steel laminated sheet using FEM simulations and experiments

Abstract

The behavior of two-layer aluminum–stainless-steel (AL-SUS) laminated sheets during deep drawing, direct and reverse redrawing processes (first and second drawing stages), have been examined by simulations and laboratory experiments. For the simulation a rigid-plastic finite element program has been used. The results of simulations are presented as the variation of drawing ratios with respect to various thickness ratios and setting conditions. They show that to achieve the highest drawing ratios in direct and reverse redrawing, the thickness ratio should be about 1 3 (one-layer aluminum and three-layer stainless-steel) and the setting conditions are opposite to each other. Considering the FEM results, laminated sheets with a thickness ratio of 71.3% aluminum and 28.7% stainless-steel were used to prepare deep drawing and redrawing experiments. The results of experiments are presented as the variation of thickness strain distribution in the drawn cup and punch load–stroke curves with respect to the setting condition. Results show that while in direct redrawing, contact of stainless-steel with the punch leads to the maximum drawing ratio, in reverse redrawing, aluminum should contact the punch in order to achieve the highest drawing ratio. An explanation for this finding is offered based on the thickness strain distribution, and punch load–stroke curves.