Analysis of Deep Drawing Process

Problematics


TTECOS studije-primerov gorenje-globoki-vlek slika3he number of phases at deep drawing process is one of the basic parameters. The natural wish is to use a single phase process for all products, which is of course not possible. Each additional phase means more and more expenses (additional tools, a need for bigger presses, more cycles, more manpower etc.). For the presented case (picture on the right) our client planned a single phase, but several doubts arose if it will be at all possible to manufacture the product in a single phase.


Problematics of deep drawing:

  • checking of manufacturability of deep drawing process on the criteria of wrinkling, thining and fracture of the blank
  • setting of the technological window of good parameters

 

Solution

With an extensive analysis in Abaqus software we were able to come to the following results:

  • selection of basic (density, young modulus, Poisson coefficient) and non-linear material data (logarythmic plastic strain curve, forming limit curve - figs 1 and 2) for prediction of plastic behaviour of blank and isolation of critical areas
  • mathematical model of the process and meshing
  • calculation of drawing and blank holder forces (figs 3 and 4)
  • display of strains in several directions on highly stressed areas and checking of the forming limit criterion (fig. 5)
  • thining analysis, which gives insight into areas of excessive thining of the blank (fig. 6)

All results indicate a safe and stable process without appearance of foreseen problems. The results were confirmed with a dedicated deep drawing analyses software package.

 

Benefits

  • elimination of risks
  • less tool trials - shorter time to market and lower costs
  • technology check prior to tool production and up-front elimination of eventual problems and excessive costs
  • use of true material data for further structural analyses with strain hardening taken into account - a very important aspect, used for a long time, enabling truly optimised products in terms of material usage and weight

 

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Figure 1: An example of logarithmic stress-strain curve for sheet metal

 

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Figure 2: Forming limit diagram (FLD)

 

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Figure 3: Blank holder force

 

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Figure 4: Drawing force

 

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Figure 5: The results of forming limit criterion

 

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Figure 6: Thinning

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