An investigation on the effects of the process parameters of hydro-mechanical deep drawing on manufacturing high-quality bimetallic spherical-conical cups

Abstract

This paper aims to analytically, experimentally, and numerically study the hydro-mechanical deep drawing (HMDD) process of bimetallic specimens. The blank included aluminum and steel sheets used to produce double-layer conical-spherical cups. The punch geometry, maximum fluid pressure, pre-bulge pressure, layer arrangement, and the drawing depth were the process parameters investigated in this article. Two criterions based on the thickness strain and thickness variation were used to assess the effects of these variables on the quality of the final product. The results of the analytical modeling and numerical simulations were verified by comparing with the related experimental data. Different outcomes were in acceptable agreement with each other. Based on the findings obtained, by increasing the fluid pressure up to 15 MPa, the quality of the final product was enhanced. Moreover, by applying the pre-bulge pressure in the HMDD process, the separation between the layers as well as the thickness variation decreased. The highest improvements in the values of the maximum thickness strain and thickness variation in the current investigation were gained to be 57% and 68%, respectively, in comparison with the traditional state of the deep drawing process.

Improvement of Formability of AISI 1006 Sheets by Hydroforming with Die in Square Deep Drawing

“…The schematic representation of the Conventional Deep Drawing process and the main hydroforming processes can be seen in Figure 1 [11,12]. Several differences regarding the tools used, contact conditions, and forming technology among the presented processes are shown in Figure 1.…”

Numerical and experimental investigations on the effects of variable cavity pressure on the formability of GLARE using hydromechanical deep drawing

“…Yaghoubi et.al in their study found that the quality and consistency of the final double-layer product were improved by applying an optimized value of fluid pressure of 15 MPa to the underside of the workpiece. The bending and tensile stresses at the punch tip were more consistently distributed in the presence of this amount of pressure, and the level of thinning was significantly reduced when compared to the usual deep drawing technique [26]. Furthermore, Jalil et al [27] provided a theoretical model for calculating the critical rupture pressure in the manufacturing of double-layered conical pieces using a hydrodynamic deep drawing process with radial pressure as a helper.…”

A comprehensive study on soundness, microstructure, and uniformity of 2024 aluminum cups hydro-mechanically drawn at elevated temperatures

“…The main objectives of their research were to reduce the forming force and improve the thickness distribution. Yaghoubi and Fereshteh-Saniee [11] studied the effect of uid pressure and pre-bulge pressure in the HMDD process to produce aluminumsteel bimetallic specimens. The results of their research showed a remarkable improvement in uniformity of the nal product in the presence of appropriate uid and pre-bulge pressures.…”