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This study investigates the thickness variation behavior of deep drawing conical products under the effect of different forming parameters such as die wall inclination angle, punch velocity, sheet thickness, and sheet metal type. Two types of sheet metal were used, low carbon (AISI 1008) and galvanized steel sheets, of 110 mm diameters circular blanks at 0.9 and 1.2mm thickness formed by tooling set (punch, die, and blank holder). The conical dies inclination angles were at 70ᵒ, 72ᵒ, and 74ᵒ where, the punch velocity was 100, 150, and 200 mm/min. Numerical simulation was conducted using ABAQUS 6.14 where a dynamic explicit solver was used to perform forming of conical products. The results show that maximum thinning occurs at punch nose radius region and maximum thickening in sidewall region and thinning are increased with the increasing of die sidewall angle and sheet thickness. In regard to sheet type, the Lankford coefficients r-value shows a great role in thinning behavior with respect to rolling (r-values direction). The results have shown a good agreement between experimental and numerical work with a maximum discrepancy of 5%.

Earing is a phenomenon that appears in deep drawing of parts produced using this process because of the anisotropic material properties. Most of, recent theories didn’t fully employ the mechanical materials properties, and ears number achieved depends on the FE simulation approaches. To anticipate the ears form issue in conical parts of AISI 1008 steel sheet deep drawing, in this work a new method is used to predict the earing formation during deep drawing. This method proposed combines the yielding limits and anisotropy r-values of the material to determine Hill48 yield criterion variables using several conical angles with several punch velocities. Equation for the value of yielding and anisotropy index for different orientation is used. AISI 1008 steel sheet is used as a case in this work, the zone of deformation or blank is partitioned radially to equal parts according to the anisotropic behavior. Hill48 yield function constants solved based on the material yielding point and anisotropy index together for the parallel deformed regions. A simulation using FE software for the process on the base of this method is executed to compare it results of lab work. and it noticed that Increasing speed may contribute slightly in decreasing the severity of anisotropy effect and this can be explained the process propagate the material need time to flow and if the speed increase this lead to increasing in strain hardening of the material[m]. Increasing die angle shows that the different between the highest point to lowest point in the cup edge may increase. This work produces a conductive and dependable way to anticipate the forms of earing during cup drawing, which will have positive effective in manufacturing implementations and numerical outcomes and shows high agreement with lab work.