Numerical and experimental investigation of dry deep drawing of aluminum alloys with conventional and coated tool surfaces

Tenner, Jennifer; Andreas, Kolja; Radius, Adrian; Merklein, Marion

doi:10.1016/j.proeng.2017.10.989

Cited by 21 publications

(10 citation statements)

References 7 publications

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“…The finite element and experimental results presented a very good match between results of failure modes, deep drawing loads, and limiting drawing ratios. Tenner et al [7] have analyzed both numerical, experimental investigations on deep drawing operation type dry of Al alloys in comparison to lubricated processes. The results revealed that with traditional equipment direct contact has produced adherent wear and thus the rectangular cup had been failed.…”

Section: Numerical and Experimental Explorations For The Formability mentioning

confidence: 99%

Numerical and Experimental Explorations for the Formability of Drawing Square Cups Through Deep Drawing Operation (January 2020)

Obaeed¹

2020

ETJ

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This study aims to examine the formability of drawing cups having square shapes through direct deep drawing process on a single action press through one pass. This can be accomplished by conducting an FE simulation and performing an experimental investigation on steel substrate type AISI 1008 blank with diameter and thickness dimensions 80, 0.5 mm respectively. To explore and analyze the formability of such a drawing process, two process parameters have been included in this work which is the speed of punch (30 and 300 mm/min) and the lubrication state (with machine oil and dry drawing). Both direct and indirect measurements of thickness strain have been adopted as an indicator of the sheet formability. The results of both FE simulation and experimental work demonstrate that the square drawing of the AISI sheet has been accomplished for all the four cups produced since the highest thinning over the cup wall does not exceed 25% of the original thickness. Generally, there is a good match between the experimental values of the indirect method and the FEM results for all models such that the largest deviation is about 25%. The direct method of thickness measurement is determined to be non-confident as strain values are practically unacceptable. Additionally, higher formability of the sheet has been realized at lower punch speeds. Furthermore, no significant difference has been observed in the formability at both speeds of punch when using a lubricant compared to the dry drawing operation.

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Section: Numerical and Experimental Explorations For The Formability mentioning

confidence: 99%

Numerical and Experimental Explorations for the Formability of Drawing Square Cups Through Deep Drawing Operation (January 2020)

Obaeed¹

2020

ETJ

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“…Using deep drawing parameters, Dwivedi et al [5] identified directions for future research, and the results of the present study demonstrated the production of aluminum alloy cups successfully. Numerous studies have been conducted on the experimental aspect of key process parameters and the impact they have on objective function [6][7][8][9][10].…”

Section: Introductionmentioning

confidence: 99%

A novel estimation of tearing limit in deep drawing process based on strain energy; experimental characterization and numerical validation

Khaboushani

Aminzadeh²,

Parvizi³

2022

Int J Adv Manuf Technol

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Deep drawing is a forming process widely used in aerospace, military, automotive, and various industries. One of the essential useful parameters in the quality of deep-drawn products is Blank Holder Force (BHF). By Controlling BHF during the process, formability has been improved, reduced forming energy, and sheet thickness. Tearing is one of the most common and crucial defects in this process due to high radial stress in the cup's wall, resulting in many limitations in this field. In this process, the blank holder force plays an indispensable role in causing tearing.Therefore, controlling blank holder force during the process would be inevitable to avoid tearing or even wrinkling. This study aims to calculate the tearing limit with new criteria in analytical dominating plasticity Equations based on the slab Method. The St14 sheet with 1 mm thickness and 200 mm diameter is used in this study. The maximum blank holder force in each stage of punch stroke with new criteria based on strain energy with three different frictional coefficients is calculated, compared, and verified with FEM simulation and experimental results. Analytical results with new criteria are also compared with previous procedures. Finally, it is realized that results related to energy criteria have a lot more similarity with FEM simulation and experimental results in comparison with the previous ones.

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“…Tenner ve ark. [28] yaptıkları çalışmada ortalama çap yöntemini kullanarak dikdörtgensel kapların derin şekillendirme kuvveti ile silindirik şeklindeki kapların derin şekillendirme kuvveti için bulunan denklemlerin literatür değerleri ile benzer sonuçlar verdiğini ifade etmişlerdir. Rivas-Menchi ve ark.…”

Section: Introductionunclassified

The Effect of Die Geometry on Cup Damages in Cold Deep Drawing of Rectangular Cups

Özek

2022

International Journal of Innovative Engineering Applications

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Derin çekme, zımba kuvveti uygulanarak sac malzemenin kalıp boşluğuna akışıdır. Derin çekmede, düz ince tabakalar arasında sacı istenen şekle getirmek için zımba kullanılarak sacı merkez kısmından kalıp boşluğuna iterek kaplar üretilmektedir. Derin çekilmiş kaplarda kabın köşe yarıçaplarında boyun oluşumu veya çatlamaların oluşması nedeniyle daha yüksek çekme oranları elde edilememektedir. Bunun için derin çekme işleminin başarılı olmasında uygun işlem parametrelerinin doğru seçilmesi önemlidir. Bu makalede, dikdörtgen geometriye sahip kapların derin çekilmesinde matris üst yüzeyine ve pot çemberinin alt yüzeyine açılar verilerek matris geometrisinin, kap kesit incelmeleri ve hasarları üzerinde olan etkileri tespit edilmiştir. Bunun için matris üst yüzeyine/pot çemberi alt yüzeyine 0°, 3°, 6° ve 9°’lik açılar verilmiştir. Pot çemberi kuvveti sabit 1800 daN ve stampa hızı da sabit 4 mm/s olarak uygulanmıştır. Derin çekme işlemlerinde, matris/stampa arası boşluk 1.2 mm, stampa uç ve kenar radyüsleri ile matris ağız yarıçapları 6 mm alınmıştır. Çalışmada kalınlığı 1 mm olan St37 çeliği kullanılmıştır. Cidar kalınlıkları Mitutoyo LH-600E hassas lineer ölçüm cihazında 0.001 hassasiyetinde nokta temaslı olarak ölçülmüştür. Kap yükseklikleri artıkça kaplardaki cidar incelmelerinin arttığı, maksimum incelmenin kabın alt kısımlarındaki köşelerde meydana geldiği ve bu değerin 0,373 mm olduğu tespit edilmiştir. Plastik deformasyonun en çok etkilediği bölge kap alt bölgesidir. Bu bölgede deformasyon sertleşmesi nedeniyle maksimum basma ve çekme kuvvetleri oluşmakta ve dolayısıyla maksimum gerilme ve sertlik bu kısımda meydana gelmiştir. Maksimum sertlik kabın tabanının olduğu bölgede ve 61.4 HRC olarak ölçülmüştür. Minimum sertlik kap üst bölgesinde ölçülmüştür. Kabın üst ağız kısımlarına doğru sertliğin daha da düştüğü ve 43.8 HRC olduğu görülmüştür. Ortalama sertlik değeri ise 53.1 HRC olarak tespit edilmiştir. Sonuç olarak, dikdörtgen geometriye sahip kapların soğuk derin çekilmesinde, matris üst yüzeyine ve pot çemberinin alt yüzeyine açılar verilerek kalıp geometrisinin, kap cidar kalınlık değişimleri ve kap hasarları üzerinde önemli bir etkisinin olduğu tespit edilmiştir.

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Numerical and experimental investigation of dry deep drawing of aluminum alloys with conventional and coated tool surfaces

Cited by 21 publications

References 7 publications

Numerical and Experimental Explorations for the Formability of Drawing Square Cups Through Deep Drawing Operation (January 2020)

Numerical and Experimental Explorations for the Formability of Drawing Square Cups Through Deep Drawing Operation (January 2020)

A novel estimation of tearing limit in deep drawing process based on strain energy; experimental characterization and numerical validation

The Effect of Die Geometry on Cup Damages in Cold Deep Drawing of Rectangular Cups

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