Optimum process parameters for increasing the drawability of square cup though conical die

Document Type : Original Article

Authors

1 Industrial Engineering Department, College of Engineering, Jazan University, KSA

2 Mechanical Engineering Department Assiut University Assiut Egypt

3 Mechanical Production Department, Faculty of technology and Education, Beni-Suef University, Beni-Suef, Egypt.

Abstract

The study introduces finite element simulation (FES) together with their corresponding experimental results for the square-cup deep drawing with simultaneous corrective ironing through conical die with no use of blank holder. The FES model has been used to investigate the optimum tool dimensions and process parameters. The independent variables of the investigation are the relative die clearances, material properties, sheet thickness, and punch surface roughness conditions. Relative die clearances of 1.5, 1.0, 0.9, 0.8 and 0.7 were used. The last four values give simultaneous corrective ironing ratios 0, 10, 20, and 30% respectively. Three kinds of sheet metals; including half hard aluminum (Al99.5w), annealed aluminum and brass (67/33 Cu-Zn) with nominal sheet thickness of 1, 1.5, 2, 2.5 and 3 mm in each metal were used. In order to study the square cup deep drawing with a high coefficient of friction at the punch-blank interface, three punches were manufactured and knurled allover to give a rough surfaces finish. Grease as a lubricant was used in the die-blank interface only. The graphs of the results of the real experiments and FE simulation regarding the drawing loads, modes of failures, and LDR's indicate very good agreement between the two ways of analysis.

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