Deep drawing of a stellar shape using finite element simulation and experimental

Abstract EN

The process of deep drawing of complex shapes is a difficult process compar ed to the process of drawing simple shapes such as cylindrical, square and rectangle because of the complex shape is subjected to the higher stresses concentranon compar ed to simple shapes.

This work aims to study the effect of the wall comer radius of punch and radial clear ance on deep drawing operanon using the experimental work and numerical simulation.

In this work, an analysis of the deep drawing process is performed for process design of stellar cup drawing.

A deep drawing die was designed and manufacturing to perform the experimental procedure required to produce a stellar cup with inner dimensions (major axrs equal to 43.7 mm and minor axis equal to 36.64 mm) formed from a circular flat sheet (80 mm diameter) comprised of low carbon steel of (0.08 %) carbon content, without any intermediate annealing.

A commercially finite element program code (ANSYS 18.0) is utilized to simulate the stellar deep dr-awing operation.

From the comparison between the results, it has been found that the thinning at cup comer increases by decreasing the wall comer radtus of the punch and the maximum thinning with th)» wall comer radius of the punch equal to (Jlcv = 2 mm) at the comer- of the minor axrs of completely drawn cup.