Experimental and theoretical study of square deep drawing

Abstract EN

This work aim to study the effect of process parameters used in square deep drawing operation such as ; die and punch profile radius, blank size, blank shape, on produced cup wall thickness, strain distribution across the wall of the drawn part, punch force, earing shape and height of the drawn cup.

3-D model of square cup (41.4mm by 41.4mm), and 0.7 mm thickness from Low carbon steel (AISI 1008), has been developed.

Because of the symmetry in the specimen geometry, only one fourth portion of the model was needed to be analyzed using finite element method, a commercial available finite element program code (ANSYS 11), is used to perform the numerical simulation of the deep drawing operation, and the numerical results of earing shape were compared with the experimental work.

In this work, three types of blank shape (circular, square, and octagonal), with different sizes, four types of punch profile radii of 3, 5, 6, and 7mm and three types of die profile radii of 3, 5, 7mm have been chosen to form a square cup.

The results show that, excessive earing will appear in the square cup when square blank was used, due to excessive material in the corner and minimum material in the flat side, and when using octagonal blank which have an equivalent surface area to the square blank, the earing in the cup corner is reduced because of extraction of the excessive material from the corner of the blank.

The best results were obtained from the circular blank, according to useful drawing height and earing.