Application of ductile fracture criterion to manufacture of aluminium liner by drawing and ironing processes

Ball ironing test (BIT) was proposed to evaluate the tribological conditions of the combined drawing and ironing process for thick sheets. This process was used to produce the products with controlled thickness at the side wall, such as pulleys. Finite Element Modeling (FEM) was utilized to study the effects of the main geometrical parameters on friction from the BIT results and thereby design suitable tooling geometries. Clearance to thickness ratio (c/t), inner die radius (rd) and inner diameter of specimen (di) were adopted as process and specimen parameters. The results of the BIT comprised the maximum load and final height of specimen. Slope sensitivity (λ) in the results was introduced to evaluate the friction sensitivity. According to the simulation, the maximum load was highly sensitive to the friction and was thus used as a friction indicator. Friction Calibration Curve (FCC) was established and fitted on the basic of a simplified mathematical model as a function of the maximum load and friction factor (m). The BIT with various types of lubricants was performed experimentally to evaluate the performances of the lubricants and approximate the friction factors. The solid lubricant, Zn-Ph coating, provided the least forming with m of 0.03. The liquid lubricant, oil with EP (extreme pressure) additives, performed similarly to the Zn-Ph coating with m of 0.07. In conclusion, the BIT test performed very well in ranking the lubricants and determining the friction value of the combined drawing and ironing process for thick sheets.

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Friction Evaluation for Combined Drawing and Ironing Process With Thick Sheet by Ball Ironing Test

Sae-eaw

Aue‐u‐lan

2020

Journal of Manufacturing Science and Engineering

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Fracture behaviour of aluminium alloy sheet under roller hemming process

Yang

Dan

2015

Materials Research Innovations

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Application of ductile fracture criterion to manufacture of aluminium liner by drawing and ironing processes

Cited by 2 publications

References 8 publications

Friction Evaluation for Combined Drawing and Ironing Process With Thick Sheet by Ball Ironing Test

Friction Evaluation for Combined Drawing and Ironing Process With Thick Sheet by Ball Ironing Test

Fracture behaviour of aluminium alloy sheet under roller hemming process

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