Study of the limiting parameters of deep drawing of sheet blanks made of heat-resistant copper alloys

Abstract

This article studies the mechanism of thin-walled workpiece deep drawing in the mould with a conical die and determines the forming limit state that occurs at the time of the bottom detachment in the radius part of the punch when stresses in the meridional direction reach their maximum value. This condition is determined by a decrease in the workpiece edge size at the stage of slow material hardening and a decrease in the workpiece flange area that are main factors hindering the process. This condition makes it possible to establish a criterion used to determine the limiting drawing ratio (ratio of the diameter of the workpiece to the diameter of the part), namely: equality of meridional stresses in the punch radius rounding area and the material tensile strength. The paper establishes the effect of the workpiece material strength properties, friction and die taper on the limiting drawing ratio. A change in the plastic and strength properties of the BrKh08 heat-resistant copper alloy (tensile strength, yield strength) does not affect the material hardening constant values and practically does not affect the limiting drawing ratio. The paper uses a comprehensive research method including theoretical analysis and modeling in the ANSYS/LS-DYNA software with input data for the 1.35 mm thick workpiece 100 mm in diameter made of BrKh08. The article presents computer simulation stages indicating main process parameters such as the workpiece material model, mechanical properties, type of elements, kinematic loads, conditions of contact interaction between elements, etc. Process simulation results confirmed theoretical conclusions necessary for the process implementation without part defects.