Deep drawing process is a very complex process which controls a lot of parameters and the associated defects. The aims of this research are to discuss the effect of parameters of the process utilized in square deep drawing process such ; material properties, blank size, blank shape on the height and shape of earing defect appear of the drawn cup. Three dimensions model from low carbon steel (AISI 1008) with thickness 0.7mm of square cup (41.4mm by 41.4mm). The finite element software (ANSYS 11) was utilized to carry out the numerical simulation of the deep drawing process, and the experimental work result of earing was compared with numerical of earing shape result. In this work, three types of the radius of die entry of 3, 5, 7mm, three shapes of the blank (circular, octagonal, and square) with various diameters, four types of radius of the punch profile of 3, 5, 6, and 7mm had been selected to form a cup with square sides. The results show that, The circular blank give the best results according to earing defect and useful height of the drawn cup, when square shape of blanks were utilized, excessive earing will show in the square cup, due to non-uniform distribution of blank material around the perimeter of the die cavity, minimum material in the flat side and too much material found in the die corner, while when using octagonal shape of blanks which have a same surface area to the square blank, the earing will reduce in the corner of the cup due to extract of the too much material from the blank corners. The results showed a high agreement between the experimental work and numerical simulation reached to 85 % in terms of the shapes and lengths of the earing appearing in the square cups.
the quality of the cups drawn in the deep drawing process are secured by the rate of metal flow into the die cavity, efficiently control on the metal flow can reduce and eliminate a lot of defects such as wrinkling, tearing and earing especially in the square deep drawing due to the non-uniform stresses induced along die cavity. This control is obtained using a restraining force supplied by blank holder tool or draw beads or both. Therefore this research focuses on the study these parameters numerically and experimentally. Ansys software based on finite element method was used to model and analyze the influence of blank holder gap and draw bead parameters in the forming process. Appropriate number of the experiments were done to compare and verify the results obtained in the numerical simulation.
The paper presents an analysis of the multistage deep drawing process considering the three deformation stages namely drawing reverse and reverse redrawing respectively. This work aim to study the mechanism of deformation during the redrawing process where the second and the third stages were done in reverse redrawing and study the effect of this mechanism on produced cup wall thickness, strain distribution across the wall of the drawn part. 2-D model of cylindrical cup (46.75mm) diameter has been developed in the first stage from sheet with thickness (0.5mm) of the low carbon steel (AISI 1008) and (85mm) diameter, while for second and third stages of drawing a punch diameter (32.725mm, 27.489mm) respectively, and inside diameter of dies equal to (33.825mm, 28.589mm) respectively, the clearance is chosen for three stage equal to 0.55mm. A commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the multistage deep drawing. The results show that, when considering multi-stage drawing, the task is even more difficult because the strain and thickness distribution resulting from the first stage will influence the subsequent results, increase in thinning in the wall cup will appear in the second and third stages. Finally this work introduces new method (multi reverse redrawing) to produce circular cup throw three stages of drawing reduction in one stroke without the need to the loading and unloading the tools among the stages as in direct redrawing which means reducing the cost, time, efforts and enhancing cup production.
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