The effect of heating temperature and methods towards the formability of deep drawn square metal cup

Abstract

The effect of heating temperature and methods towards the formability of deep drawn square metal cup Abstract. Deep drawing operation is one of the most crucial sheet metal forming processes in industrial applications, but it usually requires expensive multi-step production processes, which is necessary in order to produce complex parts. On top of that, room temperature may cause poor formability or failure due to mechanical properties of the material. The objective of this study is to investigate the effects of heating temperature and the most efficient heating position to perform warm square deep drawing operation without failure. Besides that, this study also aims to compare the thickness distribution of drawn cup's profile obtained from experiment and finite element analysis. A warm formability study of aluminium, mild steel and stainless steel sheet metals are tested by deep drawing experimental methods. The Taguchi approach, which applies L9 orthogonal array, is used to conduct experiments. Different sizes of square blanks are deep drawn at room temperature, 100°C, 150°C and 200°C using three heating techniques, which are heating die only, heating punch only and heating both the die and punch. The results show that warm deep drawing process has more uniform thickness distribution within the square cup profile compared to room temperature condition. Furthermore, maximum thinning condition at the punch corner is noticeably reduced. Lower and upper limit of heating temperature exists, as there is a low and hightemperature failure. Combination of stainless steel with 45 mm blank size, heating temperature of 150°C and die heating technique is optimal in order to obtain uniform thickness distribution in square cup deep drawing process.

A life cycle analysis of novel lightweight composite processes: Reducing the environmental footprint of automotive structures

“…In the variothermal processes (TP-cRTM and mTP-RTM) the energy for mold cooling was calculated over the power (Sánchez et al, 2018) and the used time. The energy for preheating the fabric for the stamp forming (200 • C) and the coil for the deep drawing (steel: 200 • C, aluminum: 240 • C) was calculated over the thermodynamics considering the temperature needed for each material (Basril et al, 2017). Table 4 reports all the details about the inventory data related to the different processes.…”

Effects of Temperature on Deep Drawing of an Aluminum Alloy for Different Yield Criteria and Hardening Models

“…To determine the appropriate parameters and effects of the heating methods and temperature on formability, experimental methods are generally used in deep drawing process. Basril et al [1] experimentally investigated effects of temperature and heating methods on formability of square cup deep drawing process by heating die only, punch only and heating both. By comparing thickness distribution of aluminum, mild steel and stainless steel materials for four different temperatures, optimal result was obtained to get uniform thickness distribution.…”