Simulation-Based Designed Process for Optimization of Blank Shape in the Deep Drawing Process

Abstract

Deep drawing is a metal forming process used to form cups from sheet metal. When a sheet metal of high anisotropy is used in the deep drawing process, ears are formed. These ears are formed due to high anisotropy of the sheet metal and friction between blank and die/holder. In present work, a simulation-based design process is proposed for optimization of the blank shape to minimize ears formation. A finite element analysis is done to simulate the deep drawing process of cylindrical cups. Effect of both, anisotropy and friction, is considered while performing the analysis. The material considered is extra deep drawing steel. Hill anisotropic yield is used to model the anisotropy of sheet. Circumference of the blank is divided by several equally spaced points. To modify the shape of the blank polar coordinates of these points is used. The radial dimension of these points will change while keeping the angle constant. Radial dimensions will change according to the difference between the height of the cup at various points and target height. This difference is noted as an error at these points. This process is iterated until the maximum error is minimized. ABAQUS/CAE is used to perform finite element analysis, and Isight is used to automate the execution of the iterative process. Their combination makes a simulation-based designed process for optimization of blank shape in deep drawing operation.