Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process

H. Zein; M. El-Sherbiny; M. Abd-Rabou; M. El Shazly

doi:10.12691/ajme-1-2-1

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Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process

H. Zein¹, M. El-Sherbiny^1,, M. Abd-Rabou¹, M. El Shazly¹

¹Mechanical Design and Production Department, Faculty of Engineering, Cairo University, Giza, Egypt

Abstract

1. Introduction

2. Simulation of Deep Drawing Process

3. Validation of The Model

4. Results and Discussion

5. Conclusion

References

Abstract

Prediction of the forming results, determination of the thickness distribution and the thinning of the sheet metal blank will decrease the production cost through saving material and production time. In this paper, A Finite Element (FE) model is developed for the 3-D numerical simulation of deep drawing process (Parametric Analysis) by using ABAQUS/EXPLICIT FEA program with the proper material properties (anisotropic material) and simplified boundary conditions. The FE results are compared with experimental results for validation. The developed model can predict the thickness distribution and thinning of the blank with the die design parameters (geometrical and physical parameters). Furthermore, with numerical simulation, working parameters can be optimized without expensive shop trials.

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Keywords: finite element, parametric analysis, geometrical parameters, thickness distribution, thinning

American Journal of Mechanical Engineering, 2013 1 (2), pp 20-29.
DOI: 10.12691/ajme-1-2-1

Received December 30, 2012; Revised April 14, 2013; Accepted April 15, 2013

Cite this article:

Zein, H., et al. "Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process." American Journal of Mechanical Engineering 1.2 (2013): 20-29.

Zein, H. , El-Sherbiny, M. , Abd-Rabou, M. , & Shazly, M. E. (2013). Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process. American Journal of Mechanical Engineering, 1(2), 20-29.

Zein, H., M. El-Sherbiny, M. Abd-Rabou, and M. El Shazly. "Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process." American Journal of Mechanical Engineering 1, no. 2 (2013): 20-29.

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1. Introduction

Currently, the demand for metal containers in the world is in the order of 410 billion units per annum. Out of this, drink cans account for 320 billion and processed food cans account for 75 billion. It is also known, that for the majority of food and drink containers, the cost of the processed metal accounts for 50-70% of the total cost ^[1]. From the manufacturer’s point of view, a reduction in material usage is of massive importance to cost reductions.

Reduction of material can be done by decreasing the wall thickness of the containers, whilst also retaining adequate strength to allow the container to serve its purpose, without fear of failure. The designer must meet these expectations, but also, must determine the material requirements and properties which are suitable for the food or drink being packaged. Traditionally, this process, as well as most metal forming techniques have been tested experimentally using trial-and-error or empirical methods, which are expensive and time consuming approaches, as dies, blank holders and punches need to be manufactured.

The objective of the work is to successfully simulate the deep drawing process and validate the results, by making a comparison with previously published literature. The literature contains both experimental and numerical results which are in agreement with each other and therefore is being set as the benchmark to for comparison purposes.

The incentive for doing this research is that deep drawing has come to a stage in the current industrialized world that requires the most efficient, low-cost, manufacturing route to be taken at all times.

The successful simulation of the deep drawing process is very much dependent on successful modeling of the deep drawing process for numerical analysis.

By making use of finite element analysis and statistical methods, the prediction of results such as the punch force, the blank holder force, the thickness distribution through sections of the metal and the lubrication requirements can be determined. This can significantly reduce the production costs, for higher quality containers by reducing the lead time to production and provides engineers the ability to promptly respond to market changes. In doing this, the level of knowledge in how various materials interact at the contact surfaces are enhanced, and the data for dealing with specific materials are also increased, which is another positive outcome.

The first of these works is published by Colgan and Monaghan ^[2] which has taken a statistical approach, based on experimental design using orthogonal arrays to ascertain which factors most influence the deep drawing process. The geometries for the deep drawing process have been reproduced, and a critical comparison was made for the products. 400 tests were carried out on blanks cut from drawing quality mild steel EN10130 FeP01 of 1mm thickness. The authors explain that for the experimental component of the research, hydraulic cylinders were used to deliver the blank holder force. They also reported that a pressure gauge was used to measure the pressure in the cylinders in conjunction with a needle valve. Although providing adequate results, they suggested, it would be desirable to employ the use of strain gauges in this instance, so as to gain a higher level of accuracy and confidence in the values obtained.

This work established that the punch/die radii have the greatest effect on the thickness of the formed mild steel cups. It was made apparent that the smaller the die radii, the greater the force on the blank, resulting in thinner wall thicknesses. It was also shown that the type of lubrication is very much affecting the force on the punch. Although Colgan and Monahan’s work ^[2], concluded that the die radii were noted as a prominent factor, they did not provide enough substance to account for other factors affecting the deep drawing process.

The problem is also addressed, in another approach, by Demirci et al, ^[3] for the deep drawing process of AL1050 by performing experiments and finite element analysis using ANSYS/LS-DYNA, investigating the effects of the blank holder forces on differences in the cup wall thickness. The paper shows that under constant pressure the base of drawn cups remains at a constant value until thickness drops dramatically near the cup corners and follows exponential variation towards the outer edge on the cup flange. Taking into account the anisotropic properties of the material they concluded that forces exceeding 10MPa may result in tearing in the cup walls.

A paper published by Waleed Khalid Jawad ^[4] confirms the previously stated point that increasing the punch radii can slightly decrease the punch load and vice versa. He investigated the effects of punch radii on maintaining the interfacial contact between the punch and the blank, and punch load on thickness through a section of the drawn cup, and finally predicted the resulting localized strain and stress distribution. He concluded that frictional forces act mainly through the edge of the punch in a shearing manner, with little effect on the flat section.

Vladimirov et al ^[5] presented the derivation of a finite strain material model for plastic anisotropy and nonlinear kinematic and isotropic hardening. The work is applied numerically to the drawing of cylindrical and square shaped cups. They show that the numerical simulations, can be suitably extracted from the complex mathematical material models and that the phenomena of anisotropic properties can still be accounted for even with large deformations. They further go on to show the applicability of the mathematical work to account for the occurrence of earring during the drawing process.

Fereshteh-Saniee and Montazeran ^[6] predicted forming load, by using various finite element types, and the strain thickness distributions are produced, as reported in ^[4]. The authors also show that the use of shell 51 elements of the finite element package give a much higher agreement with the experimental results, as compared with the results using visco solid 106 elements. In making these comparisons, Fereshteh-Saniee and Montazeran use a formula derived by Siebel in ^[7] to produce an analytical solution to which the level of agreement between the various methods can generally be accepted.

Meguid and Refaat ^[8] used a method of variation inequalities to develop an analytical method to model the frictional contact in elastoplastic models which undergo large deformations. The effect of nonlinearities arising due to either the geometry or the materials used in the model is handled by using the updated Lagrange formulation.

Having arrived at a point where the material can be modeled to a very high degree of accuracy and the forming loads can be predicted to complete the drawing process, one may consider various frictional combinations at the contacting surfaces aiming at minimizing such forming loads, and hence cost analysis can be carried out for the manufacturing process of the container.

This paper intends to approach the deep drawing process of thin walled, mild steel, cylindrical containers, by means of a finite element analysis.

2. Simulation of Deep Drawing Process

2.1. Finite Element Model

Figure 1 shows a sketch for drawing a circular cup. The process is described in the following steps: The circular blank is inserted between die and blank holder; the punch move downwards; the diameter of the blank decreases with the blank being drawn into the die cavity; the flange of the blank form the perpendicular wall of the cup and the center part of the blank form the bottom of the cup. The important dimensions, Figure 2, of the blank, die, punch, and blank holder are shown in Table 1.

Figure 1. Sketch of the drawing die assembly

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	In article	CrossRef

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Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process

Science and Education Publishing

Effect of Die Design Parameters on Thinning of Sheet Metal in the Deep Drawing Process

Abstract

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Cite this article:

1. Introduction

2. Simulation of Deep Drawing Process

Table 1. Basic Geometrical Parameters

Table 2. Blank Material

Table 3. Quoted parameters

3. Validation of The Model

Table 4. Geometrical Parameters

Table 5. Physical Parameters

Table 6. Comparison of thicknesses

4. Results and Discussion

Table 7. Effect of die shoulder radius (rd) on sheet metal thickness Distribution

Table 8. Effect of punch nose radius (rp) on sheet metal thickness distribution

Table 9. Effect of blank thickness (t) on sheet metal thickness distribution

Table 10. Effect of radial clearance (wc) on sheet metal thickness distribution

Table 11. Effect of blank holder force (BHF) on sheet metal thickness distribution

Table 12. Effect of punch coefficient of friction (μp ) on sheet metal thickness distribution

Table 13. Effect of holder coefficient of friction (μh ) on sheet metal thickness distribution

Table 14. Effect of die coefficient of friction (μd ) on sheet metal thickness distribution

5. Conclusion

References

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Table 8. Effect of punch nose radius (r_p) on sheet metal thickness distribution

Table 12. Effect of punch coefficient of friction (μ_p ) on sheet metal thickness distribution

Table 13. Effect of holder coefficient of friction (μ_h ) on sheet metal thickness distribution

Table 14. Effect of die coefficient of friction (μ_d ) on sheet metal thickness distribution