Effect of Tool Geometry Parameters on the Formability of a Camera Cover in the Deep Drawing Process

Abstract

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting. However, the optimization of tools including the die and punch parameters leads to a reduction of the defects and improves the quality of the products. In this paper, the formability of the camera cover by aluminum alloy A1050 in the deep drawing process was examined relating to the tool geometry parameters based on numerical and experimental analyses. The results showed that the thickness was the smallest and the stress was the highest at one of the bottom corners where the biaxial stretching was the predominant mode of deformation. The problems of the thickening at the flange area, the stretching at the side wall and the splitting at the bottom corners could be prevented when the tool parameters were optimized that related to the thickness and stress. It was clear that the optimal thickness distribution of the camera cover was obtained by the design of tools with the best values—with the die edge radius 10 times, the pocket radius on the bottom of the die 5 times, and the punch nose radius 2.5 times the sheet thickness. Additionally, the quality of the camera cover was improved with a maximum thinning of 25% experimentally, and it was within the suggested maximum allowable thickness reduction of 45% for various industrial applications after optimizing the tool geometry parameters in the deep drawing process.

Laser Powder Bed Fusion of Inconel 718 Tools for Cold Deep Drawing Applications: Optimization of Printing and Post-Processing Parameters

“…The minimum respective values for UTS and hardness for cold deep drawing tools are 1500 MPa and 50 HRC [ 28 , 29 ]. The maximum UTS value for Sample 10 is 1122.88 MPa, which is less than 1500 MPa, so DA treatment was used to increase the UTS for the as-built object using the design in Table 4 .…”

“…This cold working process can produce metal parts at temperatures from room temperature to 30% of the melting point of the material being worked. The mechanical properties of a cold drawing die include an ultimate tensile strength (UTS) of more than 1500 MPa and a hardness of more than 50 HRC [ 28 , 29 ].…”

Comparison of Friction Properties of GI Steel Plates with Various Surface Treatments

“…The formability of steel plates and the shape of the final parts made from them depend on factors such as the material (its mechanical properties and surface microgeometry) [1,2]; the forming die geometry (die clearance, radii of the punch and die) and microgeometry (roughness of contact surfaces) [3][4][5]; the technological parameters (temperature, strain rate, blank holding forces, contact pressure, etc.) [6][7][8]; the properties of the tool's material (hardness, chemical composition, structure) [9]; and the type and amount of lubricant used [10].…”

Studying the Factors Affecting Tool Vibration and Surface Quality during Turning through 3D Cutting Simulation and Machine Learning Model

“…Consequently, the development of a new and more costly model is necessary when exploring alternative scenarios. Nowadays, with the development of computer technology and numerical methods, simulations have become an essential tool in research [ 17 , 18 , 19 , 20 ]. Therefore, in this study, the authors have utilized a simulation method to simulate the turning process while focusing on using numerical calculations to analyze various factors that affect the oscillation of the tool.…”