Deep Drawing Process Parameters Research Articles

Prediction of defects in deep drawn rectangular parts using Finite Element Analysis (FEA) and Response Surface Methodology (RSM)

Abstract Deep drawing defects such as thinning and earing present challenges to sheet metal forming industry while designers tend to favour the usage of new materials and production processes. The present work introduces an integrated approach using Design of Experiment, FEA experimentation and RSM to study the effect of deep drawing process parameters and resulting defects associated with sheet metal forming processes such as thinning and earing particularly in deep drawing of non-circular parts. The Design of Experiment (DoE) is used to generate a series of experiments for different process parameters in deep drawn rectangular products which are then simulated using Simulia 2022, a finite element package. The results are then fed to statistical analysis software, Design Expert 12.0, to develop regression equations that predict minimum sheet thickness and earing defects using RSM. FE models for deep drawing of different products have been built and results have been verified through comparisons with published data. Critical process parameters were selected for investigation in the present work. Based on the results of these experiments, a two-level design of experiment is conduct to generate 64 FE experiments. The relationships between these parameters and minimum sheet thickness after drawing and earing defects are then obtained using RSM. Optimum values of different parameters are obtained for maximum sheet thickness after drawing and minimum earing.

Experimental and numerical optimization of deep drawing process parameters for square medical container design with the Taguchi method

Medical containers that sterilize surgical instruments are constantly needed in the healthcare industry. In line with this need, improvements in the fabrication of medical containers are important. Determining the design factors of medical containers fabricated by deep drawing saves time and cost. This study determined, the design factors of square medical containers and experimentally verified the deep drawing process modeled in Abaqus/Explicit finite element (FE) software. Taguchi statistical method was used to reduce the number of experiments. Blank holder force (BHF), punch radius (RP), die radius (RD), coefficient of friction between die and blank (µDB), coefficient of friction between punch and blank (µPB), coefficient of friction between holder and blank (µHB) as variable factors while selecting thickness reduction (TR) and maximum punch force (PF) were selected as output parameters. The effect of variable factors on the output parameters was determined by ANOVA analysis. As a result of the examinations, it was deter-mined that TR and PF increased as BHF, µDB and µHB values increased, whereas they decreased as RP and RD increased. On the other hand, it was determined that TR decreased and PF increased as µPB increased. In addition, the corners of the sheets were chamfered in different sizes to prevent the formation of ears in the containers. Finally, the appropriate chamfer size was determined by examining the sheet thicknesses.

Determination of optimum process parameters for minimum punch force in deep drawing using numerical simulation

This article represents the most common sheet formation method, deep drawing. This technology is employed in the production of the automotive and aerospace industries. There are various aspects that have an impact on the deep drawing process; these factors are known as the deep drawing process parameters. Finite element analysis and Taguchi Techniques are coupled to find out the optimum deep drawing parameters. Six process parameters such as die corner radius, punch corner radius, punch speed, friction between blank and die, friction between blank and blank holder and friction between blank and punch are used for analysis. Punch force is considered as response variable. The Taguchi method is employed to determine the optimal process parameters for the deep drawing process. Based on SN ratio analysis, optimum deep drawing parameters for punch force were found to be die corner radius of 7mm, punch corner radius of 7mm, punch speed of 0.2mm/s, friction between blank and die of 0.08, friction between blank and blank holder of 0.08 and friction between blank and punch of 0.10. From ANOVO, it was found that die corner radius was the most significant process parameter influencing minimum punch force.

Influence of various blank diameter in deep drawing

Forming is one of the manufacturing processes used to replicate the shape of a tool into a required product or parts. In forming, particularly in deep drawing, there are many process parameters which is to be optimized and maintained. A slight change in a particular parameter will cause a major effect in the quality of the product. The research explains the influence of diameter of the blank over other process parameters in deep drawing. Different values of punch force due to the change in diameter of the blank were obtained. The failure in the product like crack, fracture, wrinkling, and earing are analyzed for variation in diameter of the blank. At the same time, the thickness was also noted on all 3 zones of the final product. The influence over the parameters like force of the blank holder and punch is also noted. The accuracy of the product was also checked. By this, the effect of the variation of diameter of the blank is founded, and the above-mentioned values is compared with the values obtained from analyzation and values obtained when experimenting this process is compared.

Numerical optimization of warm hydromechanical deep drawing process parameters and its experimental verification

Abstract Warm Hydromechanical Deep Drawing (WHDD) is considered as an effective sheet metal forming process to overcome low formability problems of lightweight materials, such as aluminum and magnesium alloys, at room temperature. WHDD process combines the advantages of Hydromechanical Deep Drawing (HDD) and Warm Deep Drawing (WDD) processes. In this study, interactive and combined effects of Pressure (P) and Blank Holder Force (BHF) variation on the formability of the AA 5754 aluminum alloy sheets in the WHDD process were investigated experimentally and numerically. Different from available studies, the optimal fluid pressure (P) and blank holder force (BHF) profiles, which were determined numerically using adaptive FEA integrated with fuzzy logic control algorithm (aFEA-FLCA), were validated experimentally for the first time in literature. Consequently, limiting drawing ratios (LDR) of AA5754 material were recorded as 2.5, 2.625, and 3.125 for HDD, WDD, and WHDD processes, respectively. Thus, it was demonstrated that the formability of lightweight materials, such as AA5754, could be increased significantly using the WHDD process through the proposed optimization method. This method was also implemented into the WHDD of an industrial part with complex geometry, successfully forming sharp features with minimal thinning at reduced levels of force, pressure, and time. Consequently, it is reasonably to state that the method developed in this study can be adopted for the manufacturing of any other part using the WHDD process.

Investigation of Formability and Fiber Orientation in the Square Deep Drawing Process with Steel/CFRP Hybrid Composites

Recently, vehicle parts such as center pillars and impact beams used in automobiles have been requiring materials that satisfy both high strength and impact absorption. Therefore, in this study, the applicability of the forming process of CR340 (cold rolled steel sheet)/carbon fiber reinforced plastic (CFRP) hybrid composites which are a bonded material of cold rolled steel sheet having excellent formability and carbon fiber prepreg having high strength and high collision absorption in the vehicle parts was investigated. Hybrid composites are fabricated by stacking CFRP prepreg on a cold rolled steel sheet (CR340) with Zn coating. Bonding materials were used at the interface between the CFRP prepreg and steel sheet. This study investigated the formability and fiber orientation of CR340/CFRP hybrid composite after deep drawing. Square cup deep drawing tests were conducted with various process parameters to evaluate the formability of CR340/CFRP hybrid composite. The square deep drawing process parameters and the thinning rate at each position of the drawing product were measured, and the various problems encountered during the deep drawing process were reviewed with the thermal flow of epoxy. Experimental data between the forming depth and blank holding force was introduced with CFRP/CR340 with Zn coating sheet hybrid composite. The thickness variations of the materials and the fiber orientations were observed using cross sections at each position. Void and delamination defects were observed at the die round and were discussed in detail.

Optimization of multi-objective quality of TWBs square box deep-drawing process parameters

There are many process parameters involved in the deep drawing of TWBs. Each parameter has different effects on the forming quality and intercrosses each other. It is difficult to establish the relationship between the process parameters and forming quality in traditional methods. The TWBs square box part of the same material with different thickness was taking as the research object, and the common defects of the deep drawing forming part was analysed. The forming process was simulated by using finite element software DYNAFORM, considering five factors, including the thickness combination, the friction coefficient, the punch and die corner radius, the three types of variable blank holder force loading method, as well as the intercross between the variable blank holder force loading method and other factors on the forming quality of the TWBs square box part. The orthogonal test was designed to determine the important order of the various factors under different indicators, and the optimal combination of process parameters was determined by combining the AHP and grey system theory. The optimized parameters of square box part were verified by the finite element method and the deep-drawing test. The results show that the thickness distribution is reasonable, the welding seam movement is small, and there is obvious improvement in the forming quality.

Optimization of deep drawing process parameters for cylindrical cup

Abstract This paper is one of the most utilized Metal Forming Process inside the modern field. Distinctive diagnostic, numerical and experimental techniques have been created so as to dissect it. The target of this examination is to decide the variables affecting an illustration procedure and investigating the procedure by fluctuating the Die span, clear thickness, connected power and keeping the Friction as steady. In this paper Punches, clear thickness of same geometry and passes on of different geometries were drawn by utilizing CATIA programming. What's more, an exertion is made to consider the reenactment impact of principle process variation in particular kick the bucket span utilizing limited component investigation. As the FEM code, the financially accessible programming is utilized here. Aluminum composite 6061 is utilized for profound illustration. At long last exhibits an examination of the impact of bite the dust draw sweep, sheet thickness and connected power on the variety in distortion of a profound drawn cup utilizing limited component reproductions. The variety in punch power is limited via doing investigation of difference (ANOVA) for individual components and their cooperations. In this work, the mix of limited component technique and Taguchi plan of investigations and ANOVA has been connected to break down the affecting procedure parameters on Deep illustration for tube shaped cup segment.

Analysis of Dominant Process Parameters in Deep-Drawing of Paperboard

The application of the wrinkle measuring method described in Muller et al. (2017) and the subsequent evaluation algorithm of a range of deep-drawn samples were used to determine the influences and interdependencies of blankholder force, tool temperatures, and drawing height on the formation of wrinkles in paperboard. The main influences were identified and quantitatively evaluated. For the given experimental space, a regression function was derived and validated in further experiments. It was shown that a quadratic regression was superior to the previously used linear regression. The findings were discussed and compared with the results of similar experiments from past publications. Special attention was given to the wrinkles formed and the resulting quality of the formed paperboard cups. The restrictions of the data acquisition from the measuring method that was used and limitations of the model were presented to demonstrate the reliability of the results.

Finite element analysis regarding the forming behaviour of symmetric hybrid structures consisting of two sheet metal outer layers and a thermoplastic core

To face challenges like damping effects or weight reduction in the automotive sector, new hybrid material combinations are developed. One possibility is the combination of several symmetric material layers with varying material characteristics to achieve in the component production less weight and appropriate stiffness in comparison to components produced with sheet metal. This article deals with the characterization of deep drawing behaviour of layered sandwich structures. The behaviour of the several layers and the layer interaction have been taken into account for the technical design of a deep drawing process. A material layer characterization is performed. Instabilities as interlaminar failures, ruptures or wrinkling of the structure have been investigated as part of additional experimental characterization tests on the basis of various deep drawing process parameters. Finally, the experimental data is used as input for the numerical modelling and simulation of layered structures. The FE simulation includes the material behaviour of the layers and layer interactions with cohesive zone modelling. Based on the results an important contribution for prediction accuracy in the numerical simulation has been provided.

The Study of Deep Drawing of Brass-steel Laminated Sheet Composite Using Taguchi Method

Deep drawing process is one of the most applicable methods in producing industrial parts. In this process, the initial blank deforms to final product using a rigid punch and die. In this investigation, the effect of deep drawing process parameters of brass/steel laminated sheet composites on required forming force has been investigated. The process simulated using finite element method (FEM) and then validated by using experimental results. Afterward, the effect of process parameters including friction coefficient between punch and sheet (punch friction), friction coefficient between die and sheet (die friction), blank holder force and the initial blank diameter all in three different levels investigated using design of experiments (DOE) by Taguchi method. Based on four selected parameters in three levels, experiments performed by Taguchi L9 orthogonal array and then the maximum punch force of each experiment was obtained using validated FE model. Signal to noise (S/N) analysis demonstrated that the die friction is the most important parameter in deep drawing of brass/steel laminated sheet that by its reduction, the maximum punch force decreases. Also analysis of variance (ANOVA) results illustrated that the die friction and initial blank diameter are involved 53.1% and 43.4% of contribution on maximum punch force, respectively.

OPTIMIZATION OF INFLUENTIAL PROCESS PARAMETERS ON THE DEEP DRAWING OF ALUMINIUM 6061 SHEET USING TAGUCHI AND FINITE ELEMENT METHOD

The plastic deformation behavior of axis symmetric aluminium 6061 cups was determined by analyzing the four important deep drawing process parameters, namely blank temperature, die edge radius, blank holder force and friction coefficient. Taguchi techniques along with finite element method (FEM) were used to determine the importance of process parameters. The Taguchi method was used to analyze the influence of each process parameter. From the deformation result and analysis of variance (ANOVA), it was determined that the temperature of the blank has a major influence on the deformation characteristic of aluminium 6061 sheets followed by die edge radius, coefficient of friction, and blank holder force. The optimum levels of the four factors in determining the deformed cup heights are found to be blank temperature of 450°C, die edge radius of 14 mm, coefficient of friction of 0.60 and blank holder force of 9 KN.

Investigation of the effect of hydromechanical deep drawing process parameters on formability of AA5754 sheets metals by using neuro-fuzzy forecasting approach

Adaptive neural-network based fuzzy logic inference system (ANFIS) is a useful method instead of costly Finite Element Analysis (FEA) in order to reduce investigation cost of forming processes. In this research, the effect of hydromechanical deep drawing (HDD) process parameters on AA5754-O sheet was investigated by FE simulations with analysis of variance (ANOVA) and Adaptive Neuro-Fuzzy Modeling approach. In order to determine the prediction error of the ANFIS model according to FEA, firstly a series of FEA of the HDD process were conducted according to Taguchi's Design of Experiment Method (DOE). The results of the FEA were confirmed by comparing the thickness distributions of the formed cups by experimentally and numerically. Moreover an adaptive neural-network based fuzzy logic inference system (ANFIS) was created according to results of simulation to predict the maximum thinning of AA5754-O sheet without needing FE simulations. The calculation performances of the ANFIS model were determined by comparing the estimated results with the results of the FE simulations. By using the results of the FE simulations which were conducted according to a matrix plan, the effects of the parameters to the thinning of the blank were determined by the analysis of variance (ANOVA) method. ABAQUS and MATLAB/ANFIS/Simulink softwares were used to realize and simulate proposed techniques. Mean error of prediction result of ANFIS is found as 0.89% according to FEA.

Study of the Parameters of Deep Drawing Process Based on the Simulation of Dynaform

A simulation of deep drawing process on the sheet metal was done by using Dynaform, the influence of blank holder force, deep drawing speed and friction coefficient on the forming speed of sheet metal in the deep drawing process were got. The forming speed of sheet metal determines the quality of deep drawing, in the deep drawing process the blank holder force and the deep drawing speed are controllable parameters, the friction coefficient can be intervened and controlled, and it’s a manifestation of the interaction of all parameters, the main factors which influence the friction coefficient just have blank holder force, deep drawing speed and lubrication except the material. The conclusion of this study provides the basic data for the analysis of the lubrication of mould, the study of lubricant and the prediction of the service life of deep drawing die.

Influence of process parameters on the cup drawing of aluminium 7075 sheet

AA7075 is one of the most important structural materials extensively used in automobile and aerospace industries. Extensive research on its formability aspects is required to develop useful components of complex shapes out of this material. One of the ways to measure the formability is to find its deep drawability characteristics. In this study, the significance of three important deep drawing process parameters namely blank temperature, die arc radius and punch velocity on the deep drawing characteristics of aluminium 7075 sheet was determined. The combination of finite element method and Taguchi analysis was used to determine the influence of process parameters. Simulations were carried out as per orthogonal array using DEFORM 2D software. Based on the predicted deformation of deep drawn cup and analysis of variance test (Anova), it was observed that blank temperature has greatest influence on the formability of aluminium material followed by punch velocity and die arc radius. Multiple regression analysis techniques were applied in modelling the behaviour of AA 7075 aluminium alloy under multistep deformation conditions.

Parametric and non-parametric modelling of earing and hardness of deep drawn cups

This study compares different approaches in modelling the earing phenomenon and hardness of cups in deep drawing process. The blank holder force (BHF), annealing temperature and annealing time of blanks before deep drawing process have been chosen as the three influential parameters on the earing and hardness. To obtain mathematical models for the earing and hardness of the deep drawn cups, the methodology of artificial neural networks have been used. Bayesian network, radial basis function network, Gaussian processes and multilayer perceptron are four different ANN approaches that have been used for the modelling. The research has been conducted on a cold rolled Al–Fe–Si (AA8011A) aluminium sheet. After obtaining the mathematical models describing the influence of BHF and annealing on hardness and earing, a comparison of the proposed models has been performed. A search for the optimal parameters of deep drawing process has been carried out.

Forming of High Strength/Low Formability Metal Sheets at Elevated Temperatures

The purpose of this study is to determine the limits and to investigate the efficiency of sheet metal forming process at elevated ( warm / hot ) temperatures. Deep drawing of HSLA / UHSLA steels, aluminium, titanium and magnesium alloys in an effective way is possible only at elevated temperatures and has some indefinitenesses. In the study, deep drawing simulations are realized with a titanium copper alloy and a low alloy steel to investigate the deep drawability of high strength / low formability metal sheets. The comparison of the results obtained from this study with the other experimental, analytical and computer aided studies found from the literature showed that the results are coherent. From the studies its understood that, the critical temperature that makes the deep drawability maximum differs from material to material. This temperature is a complex function of the material and deep drawing process parameters.

A comparative study of deep drawing with conventional, isostatic, and hydrostatic pressure

Deep drawing with radial fluid pressure — which also goes by the name “fluid pressure forming” — is a newly developing sheet metal forming process that has many advantages over the conventional deep drawing process: a significant application of the technique is its — indispensible — employment in the area of the forming of the so-called high strength difficult metals. A new tool set-up has been designed and developed so that it can be used on a double-action hydraulic press for investigating deep drawing process parameters in both hydrostatic and isostatic environments. In the present paper a comparative study has been made of the results of deep drawing with conventional, with isostatic and with hydrostatic pressure. Experiments which were performed on aluminium sheets provide better results and more efficient energy utilisation when using hydrostatic pressure than when using isostatic and conventional techniques.

An experimental study on effect of process parameters in deep drawing using Taguchi technique

The effects of various deep drawing process parameters were determined by experimental study with the use of Taguchi fractional factorial design and analysis of variance for AA6111 Aluminum alloy. The optimum process parameters were determined based on their influence on the thickness variation at different regions of the blank material. Three important process parameters i.e., punch nose radius, die shoulder radius and blankholder force were investigated in this study. Plan of experiments based on Taguchi’s technique were used for acquiring the data. An orthogonal array, the signal to noise ratio and the analysis of variance were employed to investigate the deep drawability characteristics. Influence on thickness due to variation of these parameters was individually evaluated in terms of percentage. The results showed that the blankholder force (56.98%) was the most significant parameter followed by punch nose radius (30.12%) and the least influence (12.90%) was with die profile radius.Keywords: Axisymmetric deep drawing, Taguchi method, orthogonal array, S/N ratio, anova