Sensitivity Analysis For Determination The Optimal Blank Shape For Hydromechanical Deep Drawing Of Steel Cups

Abstract

In the deep drawing of cups, the earing defects are caused by planar anisotropy in the sheet. Several methods have been developed to predicting the optimal blank to avoid the formation of ears. In the deep drawing processes, the use of an optimal blank shape not only saves the material but also it may reduce the occurrence of defects e.g. wrinkling and tearing. In addition, finding the desirable flange contour, eliminate the trimming step in the deep drawing of parts with flange. In this study, a systematic method based on sensitivity analysis has been used to find the optimal blank to obtain a desirable flange contour for a cylindrical cup by hydromechanical deep drawing process. With the aid of a well‐known dynamic explicit analysis code ABAQUS; optimum initial blank shape has been obtained. With the predicted optimal blank, both computer simulation and experiment are performed and the effect of blank shape on the some parameters such as thickness distribution and blank holder force during the forming process were investigated. It is shown that formed cup with an optimum blank shape has a better thickness distribution in the both rolled and perpendicular of rolled direction. And it was shown that the blank holder force of modified blank is higher than circular blank.