Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes

Abstract

Deep drawing process is important sheet metal forming processes and is done either with or without blank holder. In this research, there is another innovative method that combines both two modes drawing process at the same time, with the possibility of ironing the thickness for the wall cup produced in the same process. In the first, drawing is done without a blank holder by two inclusion punches, one of which forms an initial cup. Then it creates an inclined blank holder for the drawn cup, and the other punch continues process, followed by wall thinning completing the deformation of the cup. The ironing happens when using several punches with diameters whose clearance is less than the thickness of the blank. A simulation model of the innovative process was built using the ANSYS program, while experimental work was conducted on a general testing machine, also the study effect of the process variables on the produced cups and their characteristics. The results showed that the innovative process of deep drawing led to an increase in drawing ratio that reached 2.24. This is a high percentage compared to the traditional method, also the process variables have a clear effect on the cups produced. The simulation results showed their convergence was observed between the simulation and experimental results at the same conditions. The results also showed that the values of wall thinning reached by 80% from the thickness blank value before drawing.