Deep drawing of 304 l steel sheet using vegetable oils as forming lubricants y. Sheet metal forming is an efficient and economic production process for the mass production of automotive components. How to designing a deep drawing manufacturing process. Earing is one of the major defects observed in a deep drawing process. In the deep drawing process, deformation defects such as fracture and wrinkling have been found due to large deformation. Jayaram2 1research scholar, department of mechanical engineering,malnad college of engineering, hassan karnataka state, india. Defects that occur during deep drawing of sheet metal can be controlled by careful regulation of process factors. Instead of simply increasing or decreasing the bhf, mori and uchida 9 introduced a vibrating blankholder with different frequencies.
Deep drawing of 304 l steel sheet using vegetable oils as. Deep drawing is a sheet metal forming process used industrially to produce cup shaped, boxshaped, and other. One of the primary defects that occurs in deep drawing operations is the wrinkling of sheet metal material, generally in the wall or flange of the part. Deep drawing metal parts fabrication american aluminum. Pdf this paper shows the finite element simulation of the deep drawing process where forming defects like. Mechanical and industrial engineering department, applied science university, amman 11931, jordan. Din 8584 deep drawing processes are divided into three types. The schematic drawing of the conventional deep drawing process is depicted in figure 6. The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. In sheet metal forming practice, we distinguish five basic modes of deformation.
Effect of various parameters on the wrinkling in deep. The deep drawing process is a forming process with ongoing interest. Otherwise, a good formability or product quality is related to proper part characteristics. Deep drawing mechanism, parameters, defects and recent results. This article highlights only the most frequently violated design and build principles. Deep drawing process to produce square cup is very complex process due to a lot. In deep drawing process the main objectives are to obtain defect less or minimum defects in product. Earing is a defect that occurs due to uneven drawing as shown in figure.
Download limit exceeded you have exceeded your daily download allowance. It will be guidance for the practical production engineers engaged in this spinning area. The stress in the flange region during the deep drawing process is a combination of radial tensile drawing stress and a tangential compressive stress hoop stress. A flat sheet metal blank is formed into a hollow body open on one side or a hollow body is formed into a hollow body with a smaller crosssection. Sheet metal forming massachusetts institute of technology. Earing is one of the major defects observed during deep drawing process due to anisotropic nature of sheet metal. In this experiment both steel and copper were taken as a base material and deep drawing process was finished with different parameters and defect was analysed. While these calculations can predict displacem ents, they cannot reveal the visual impact of the defect. Request pdf study of earing defect during deep drawing process with finite element simulation deep drawing is one of widely used sheet metal working process in industries to produce cup shaped. We maintain a verticallyintegrated facility with onsite engineering, designing, and prototyping services.
Some aspects of blankholder force schemes in deep drawing. Defects in deep drawing tearing maximum thinning of the cup wall occurs near the base, so, tearing of the sheet metal is most likely to occur in this region even if the stress is originating somewhere else wrinkling may often occur if the blankholder force is too low excessive thinning in areas of the sheet metal earing that is the formation. Excessive thinning in areas of the sheet metal is also an unwanted defect. Due to improper clearance and punch force, defect was occurred in drawing components. Deep drawing dd is one of the sheet metal forming processes widely used in automobile. To reduce various defects in deep drawing process it is necessary to control some parameters of deep drawing process. Hydroforming cheap tooling, no net thinning, slowish, high formability low volume batches. Because a part wrinkled during the deep drawing process will not be accepted and most likely become as scrap. Defects wrinkling in the flange wrinkling in the wall tearing earing anistropy in sheet metal surface scratch. Concordia universitymech 4216511 lecture 97 analysis of drawing measure of drawing. Analysis of deep drawing of sheet metal using the marform process. At low forming pressures, wrinkles appear in the flange, whilst at higher pressures, fracture is the main defect of the marform process. The geometry parameters used in deep drawing process are mentioned below.
Crude measures of the severity of a deep drawing operation. The workpiece material used in a deep drawing process is anisotropic in nature, due to a prior thermomechanical treatment. Effect of forming conditions on localized thinning in deep. A deep draw process may have one or more drawing operations, depending on the complexity of the part.
Effect of different lubricants on deep drawing of galvanized steel adnan i. Hashim abstract deep drawing process is one of the most widely used metalworking processes among the sheet metal forming processes in general and among the sheet metal forming processes in particular. These defects can be seen around form ed areas within largely flat panels. Shallow drawing is defined as that where the cup height is less than half the diameter. One of the primary defects that occur in deep drawing operations is the wrinkling of sheet metal material, generally in the wall or flange of the part. To eliminate earing excessive deformation in deep drawing should be avoided. Zaid abstract friction plays an important role in manufacturing some processes it is useful and required e. Identification of defects in drawing operation with remedial steps mahesh t. Causes of these are mostly too high or improper force distribution and material considerations. In their experimental work, the blank holder vibration was given by a cam mechanism and the effect of changing the frequency on the deep drawing. Study of earing defect during deep drawing process with. Forminglimit diagram a grid pattern of circles, typically 2. Deep drawing mechanism, parameters, defects and recent.
Circular cup drawing is the most basic process among the deep drawing processes. Following is a list of common defects during sheet metal operation, with sketches are shown in figure 1. Deep drawing is a sheet metal forming process which is widely used in manufacturing parts for automobile and air craft industries. The defects in the drawing operation have to be minimised for the better product or the good quality of the. Deep drawing is a sheet metal forming process which is widely used in. American aluminum company is a leading manufacturer of deep drawn parts, including cylinders, enclosures and irregular shapes. In this paper a new method to predict the onset of the wrinkling will be introduced, and results of this test will be compared with real deep drawing parts. Sheet metal is drawn in either hydraulic or mechanical presses. Pdf deep drawing mechanism, parameters, defects and recent. Paper open access related content deep drawing mechanism. In this paper, the mechanism of deformation, effect of the geometrical parameters involved and the defects encountered in. Pdf prediction of forming defects in deep drawing process by. Effects of various parameters in deep drawing process over. The manufacturing of deep, cuplike products from thin sheet metal is known as deep drawing.
The identification and the correction of these problems, which can be achieved through the early use of numerical simulation. The article summarizes the defects in drawing and factors considered in press selection for drawing. Prediction of wrinkling is a very important process for a deep drawing operation. Most common defects occurred during this process are wrinkle and tear. Metal forming processes indian institute of technology. Effects of different parameters on deep drawing process. The flange of the blank undergoes radial drawing stress and tangential compressive stress during the stamping process, which. Reduction of wrinkling defect in deep drawing process. Finite element simulation of earing defect in deep drawing finite element simulation of earing defect in deep drawing saxena, ravindra.
Definition deep drawing is the manufacturingprocess of forming sheet metal stockcalled blanks, into geometrical shapes. Pdf deep drawing mechanism, parameters, defects and. Defects in deep drawing deep drawing is a more complex operation and more things can go wrong. Defects in deep drawing tearing maximum thinning of the cup wall occurs near the base, so, tearing of the sheet metal is most likely to. Therefore, it is important to optimize the process parameters to avoid defects in the parts and to minimize production cost. Pdf deep drawing is a sheet metal forming process which is widely used in manufacturing parts for. Experimental evaluation and finite element simulation to produce. This paper also contains the comparative study of spinning and deep drawing.
Recent experiments at the institute ifu indicated that the buckling test using modified specimens can enhance accuracy for the predication of wrinkling. For general deep drawing, operations, most people define the defects as that block which can be deformed into a cylindrical cup with either a uniform flange or. Optimization of deep drawing process for circular cup forming. Blankingblanking is the process ofcutting the initial sheet coil stockinto round or shaped flatsrequired for deep drawing.
Pdf finite element simulation of earing defect in deep. Large set of manufacturing processes in which the material is deformed plastically to. Finite element simulation of earing defect in deep drawing. Sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. A number of defects can occur in a sheet metal drawn product. Deep drawing is an extensively used press working process since it eliminates expensive machining and welding operations and enables the production of components at a very high rate. Figureearing due to uneven drawing and part failure 3. In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is performed by stretching the metal in some regions.
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