Deep drawing process by simulation in the presence. Chapter 3 modelling and simulation of deep drawing process of. In deep drawing process the main objectives are to obtain defect less or minimum defects in product. Due to its enormous economical impact, the application of the. Simulation process deep drawing of tailor welded blanks dp600 and bh220 materials in tool with elastic blankholder alexander schrek alexander. Detailed experimental and numerical analysis of a cylindrical. In this paper, both rigidplastic fem simulation and experimental methods are used to systematically analyze axisymmetric deepdrawing. F riction also in uences the stresses and strains in the w orkpiece material and, hence, the. Caebased optimization methodology for stamping process of.
Table 3 shows the properties of st12 sheet metal fereshtehsaniee and montazeran 2003. Numerical and experimental investigations on deep drawing of. Based on a validated simulation model a warm forming process simulation is set up and optimised. Modelling of contact and friction in deep drawing processes.
Pdf finite element simulation of warm deep drawing process. Deep drawing is a common process in industry for manufacturing products from sheet metals. The simulation results of the warm forming process are compared with the corresponding cold forming results. Modelling and simulation of friction in deep drawing submitted by murat ba spinar in partial fulfillment of the requirements for the degree of master of science in mechanical engineering department, middle.
Mechanical model deepdrawing process modelling puts forward complex problems due to the nonlinearity of the behaviour laws, to the presence of elastoplastic transformations and to the nonconstant boundary conditions of contact with friction. One of the challenge that faces the deep drawing process is. Simulation study of deep drawing process request pdf. This paper introduces deep drawing of aluminium sheet metal at. The main goal of this work is to present a threedimensional mechanical model for the numerical simulation of the deep drawing process. Thus, simulations and physical models were created.
Instability in the work piece, also called wrinkling of the walls. Experimental material has been mutually zinccoated, with amount of zinc 75 gm 2. Numerous unconventional deep drawing techniques have recently been implemented that have helped increase the industrial uses of deep drawing. In this section, to determine the drawing force at tear moment, the deep drawing process for the st12 carbon steel plate with the standard number din 1. The phenomenon of wrinkling flange instability is specific to the process of deep drawing. Study of earing defect during deep drawing process with. The purpose of presented work is to analyze the deep drawing process of thin walled, stainless steel, cylindrical cup shape of sink basin by means of a finite element simulation. A study on a deepdrawing process with two shaping states for. Apart from its use in many other sectors, it is applied in the automotive industry for the manufacturing of car body parts. Deep drawing, springback, finite element analysis, aa5754o. The results have been obtained by means of laboratory measurements on the drawing tool as well as material simulation computed by lsdyna code. Simulation of aluminium sheet metal deep drawing at elevated. This approach was examined through simulations of a hemispherical forming process. Keywords deep drawing geometric modeling simulation deflection stress intensity aluminium alloys 6061 and 7075 ansys software manufacturing process.
The deep drawing of cylindrical cups has also been extensively studied see e. Numerical simulation of deepdrawing process sciencedirect. Oct 31, 2017 hydraulic press deep drawing process duration. Simulation of aluminium sheet metal deep drawing at. Pdf finite element simulation of a deep drawing process of. The deep drawing process is one of the more extensively used sheet metal forming process. Experimental and simulation progress on deep drawing process.
In this study, the deep drawing process of shaping the fuelfilter cup is simulated with abaqus software. This thesis friction in deep dra wing considers some aspects of friction on the deep drawing process. In this process, the forming parts are usually obtained in a singlestage, but in some conditions multistage operation is required due to geometrical complexity or formability problems. Chemical composition of material declared by producer is. Earing is one of the major defects observed in a deep drawing process due to the. Deep drawing process of the doubleaction hydraulic press fem model in this study, the deep drawing process of shaping the fuelfilter cup is simulated with abaqus software. Deepdrawing process simulation for tailorwelded blanks with. The model takes into account the large elastoplastic strains and rotations that occur in the deep drawing process.
Simulation process deep drawing of tailor welded blanks dp600. Algorithms and strategies for treatment of large deformation. In this simulation, a dry friction is chosen with coefficient of friction. Physical modelling and numerical simulation of the deep drawing. The model takes into account the large elastoplastic strains and rotations that occur in the deepdrawing process. Chapter 3 modelling and simulation of deep drawing process of circular cup onal1200usingfinite element analysis y. Deep drawing is a sheet metal forming process that involves complex material flow and force distributions. Finite element simulation of deep drawing process using solid. Caebased optimization methodology for stamping process. Circular cup drawing is the most basic process among the deep drawing processes. 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. A mechanical model used in numerical simulation should take.
Heating the material up to a temperature where the yield strength decreases and formability increases drastically is one. Chapter 3 modelling and simulation of deep drawing process. Prediction of wrinkling is a very important process for a deep drawing operation. The process is widely used for producing different products such as automotive parts, cans, sinks and housing, and the application areas are getting larger every day. Very complex parts can be achieved using deep drawing. This process increases the production costs, and can lead to an inexpedient production flow and can give problems with regard to maintaining close tolerances due to distortion during annealing process. Finite element simulation of earing defect in deep drawing. To achieve the complete virtual tryout of a component it is. The main focus of this course is on deep drawing of vehicle body parts. Simulation of deep drawing process using afdex copy. The workpiece material used in a deep drawing process is anisotropic in nature, due to a prior thermomechanical treatment. In this study, the deepdrawing process of shaping the fuelfilter cup is simulated with abaqus software. Study of the parameters of deep drawing process based on the. The process is widely used for producing different products such as automotive parts, cans, sinks and housing, and.
The main goal of this work is to present a threedimensional mechanical model for the numerical simulation of the deepdrawing process. Deep drawing is one of widely used sheet metal working process in industries to produce cup shaped components at a very high rate. Pradhan abstract deep drawing process is the mostly used sheet. Validation and robust optimization of deep drawing process by. Fem model of the deep drawing test with typical phases of the process is shown in figure 3. Introduction casting machining welding and metal forming are the main methods of manufacturing. T ogether with the deformation of sheet, friction determines the required punc h force and blankholder force. Analysis of an axisymmetric deep drawn part forming using.
The simulation of deepdrawing process has been carried out for a deepdrawing dc06 bze 7575phol steel with thickness of 0. Metal forming simulation is also helpful at the product and tool design stage to decide various parameters. Consequen tly, friction in uences the energy whic h is needed to deform a sheet material. Investigation of a new methodology for the prediction of. The deep drawing process involves a great deal of sliding of the sheet material along the tools. It is concluded the similarity between the numerical and experimental results and these is a started point in the creation of a database for tribological behaviour of materials in deep drawing processes. Sheet metal forming warm deep drawing magnesium alloy sheet finite element simulation. Prediction of draw ratio in deep drawing through software. Deep drawing for a circular cup a initial stage and. Analysis of original drawing process the existing forming process consists of 10 steps, that is, 7step, 2step and 1step drawing to form zone i, zone ii and zone iii, respectively. Request pdf simulation study of deep drawing process deep drawing process is one of the important processes in sheet metal forming. Stamping deep drawing fundamentals this course covers the fundamentals in sheet metal forming of steel, aluminum and highstrength steel, using practical examples from the automotive industry. Process simulation, process design, deep drawing, superimposed vibration, servoscrew press.
It is found that in order to adequately capture the plastic properties of hcp. Deepdrawing process of the doubleaction hydraulic press fem model in this study, the deepdrawing process of shaping the fuelfilter cup is simulated with abaqus software. According to acquired results, it can be claimed that the blankholder force values and force distribution have a significant influence on the deepdrawing process of tailorwelded blanks. Finite element simulation of deep drawing process using solid element. Finite element simulation of the warm deep drawing process in. In recent years, due to its low density and high strength. Under certain conditions, this sliding will cause friction between the tools and the material. Analysis of optimization of blank holding force in deep. Numerical simulation of process consists of two steps. Deep drawing process is the mostly used sheet forming process. Simulation of deep drawing process using afdex copy free download as powerpoint presentation. According to acquired results, it can be claimed that the blankholder force values and force distribution have a significant influence on the deep drawing process of tailorwelded blanks. Analysis results in the process of deep drawing up and coming changes in the thickness of metal sheet.
Deep drawing dd is one of the sheet metal forming processes widely used in automobile. Pdf finite element simulation of a deep drawing process. The simulation of deep drawing process has been carried out for a deep drawing dc06 bze 7575phol steel with thickness of 0. The second step was drawing of cylindrical cup by the punch. In figure 2 tis presented sheet thickness in mm there is thinning in the area of the bottom cover and the. These processes include hydroforming, hydromechanical deep drawing, aquadrawing, hydraulic deep drawing, the guerin process and the marform process.
Modelling and simulation of deep drawing process of circular cup. Pdf numerical simulation of the deep drawing process with. B h f is an important parameter in deep drawing process. Threedimensional numerical simulation of the deepdrawing. The design and control of a deep drawing process depends not only on the workpiece material, but also on the condition at the tool workpiece interface, the mechanics of plastic deformation and the equipment used. Deep drawing, deform3d, draw reduction ratio method, fem simulation, ldr. Influence of the plastic anisotropy modelling in the reverse. Prediction of wrinkling is a very important process for a deepdrawing operation. Successful deep drawing is a combination of many important factors. Pdf threedimensional numerical simulation of the deep. Deep drawing is a process for shaping flat sheets into cupshaped articles without fracture or excessive localized thinning. Root cause analysis of deep drawing processes with. Optimization of deep drawing process for circular cup forming.
Finite element simulation of deep drawing of aluminium alloy. Because a part wrinkled during the deep drawing process will not be accepted and most likely become as scrap. Deep drawing is an extensively used press working process since it eliminates expensive machining and welding operations and enables the production of components at a very high rate. Nov 15, 2017 the results have been obtained by means of laboratory measurements on the drawing tool as well as material simulation computed by lsdyna code.
Improving the drawing limits of the material is an important issue, especially when forming materials with limited formability. Deep drawing is one of the most widely used processes in sheet metal forming. The barlat 1989 material model is adopted for modelling the plastic response of the material and the necessary input data is examined. Formability analysis of deep drawing process by finite. Fem model of the deep drawing test with typical phases of the. Sheet metal forming is a complex process involving geometric, material and. This article highlights only the most frequently violated design and build principles. Earing is one of the major defects observed in a deep drawing process. Ozkoc automatic hydraulic press line transfer press filter production duration. The process was simulated by finite element analysis using a commercial implicit fem package abaqusstandard to establish the base for our following analysis. The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. This method is used in the automobile and aerospace industries and also used for the.
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