The influence of different forming techniques on the performance and outcomes of the deep drawing process for intricate geometries

Abstract

This study explores the creation of a complex, eight-vertex shape through a deep-drawing process using two distinct approaches. The first, known as the direct method, involves forming the desired shape directly from metal sheets. The second approach, referred to as the indirect method, requires an intermediate step where a cylindrical shape is initially drawn and then reshaped into the final complex form through a redrawing process. A comparison was conducted between the two methods to evaluate their performance in terms of drawing force, thickness distri-bution, as well as stress and strain behavior. Low-carbon steel (1008-AISI) sheets with a thickness of 0.7 mm and a diameter of 80 mm were utilized for the experiments. The simulation of these processes was carried out using ANSYS 18.0 software. The findings revealed that the maximum drawing force recorded during the direct drawing process was 41 KN (experimental) and 30 KN (finite element simulation). Additionally, the redrawing process led to an increase in effective stress and strain, reaching peak values of 835.23 MPa (stress) and 0.442 (strain, simulation) or 0.345 (strain, experimental) in the minor axis curvature region. The redrawing process also resulted in the most significant thinning of 7.143% (simulation) and 5.722% (experimental) at the same curvature zone. The direct drawing process, however, exhibited superior uniformity in thickness, stress, and strain distributions.