Sensitivity analysis and statistical process optimisation of deep drawing of AA 6061 sheet material

Abstract

Deep drawing, besides its importance as a forming process, also serves as a basic test for sheet metal formability. The elastic deformation within the overall amount of deformation is not desired and leads to springback in the drawn components. This affects the dimension and shape of the formed cups. Fundamental understanding of variation of the process parameters has become essential for accurate rapid design of tooling and processes in early design stage. Therefore, in the present study, the effect of parameters such as the die shoulder radius, punch nose radius and the blank holder force on the deep drawing of AA 6061 aluminium alloy is studied and mathematical model was developed using response surface methodology. The parameters were optimised for minimum springback. Sensitivity analysis was carried out to evaluate the effects of each process parameter on springback. The optimal values of die shoulder radius, punch nose radius and blank holder force for minimising the springback were found to be 3 mm, 3 mm and 6 kN respectively.

Multi Objective Optimization of Deep Drawing of AA 6061 Sheet Material

“…The quality characteristics chosen for the experiment should reflect as accurately as possible the design parameters under study. Though the choice of these responses were discussed in detail vide articles [3][4], a modest discussion of the responses is given here for clear understanding of this study.…”

“…In this study, the results of the research articles [3][4], each considering three different single responses, namely springback, thickness variation and punch force, published by the same author were taken for multi-objective optimization.…”

“…The articles [3][4] suggest that the deep drawing parameters namely, the punch nose radius (PR), die shoulder radius (DR) and blank holder force (BHF) are important parameters in the deep drawing of AA 6061 sheet material. The selection and influences of the parameters have been discussed sufficiently in the articles.…”