This paper shows the finite element simulation of the deep drawing process where forming defects like wrinkling and material erosion of blank is eliminated by using lubricant within the surface. If you continue browsing the site, you agree to the use of cookies on this website. Optimization of process parameters in sheet metal forming is an important task to. Due to improper clearance and punch force, defect was occurred in drawing components. Formability and related characteristics are essential for deep drawing of paperbased materials. Gerdooei school of mechanical engineering, shahrood university of technology, shahrood 3619995161, iran article info. Standard cabinet specs standard cabinet specs door styles. The most common use is no doubt in the straightening of gear box and steering rack rods. How deep can you draw metal to form a deep drawing. These processes include hydroforming, hydromechanical deep drawing, aquadrawing, hydraulic deep drawing, the guerin process and the marform process.
A forming process which occurs under a combination of tensile and compressive conditions 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 deep drawing processes are divided into three types. Drawing ratio, punch corner radius, punch speed etc. In this section, the main parameters affecting the deep drawing process are given and discussed which include. Deep drawing is a sheet metal forming process that involves complex material flow and force distributions. Hence, for each new make and model of automobile designed, a new rack must be created or timely and costly modifications must be made to the existing racks.
Prediction of earing in deep drawing of anisotropic. Deep drawing steel is a widely used process for forming steel metal sheet into box or cuplike structures. Deep drawing deep drawing analysis other sheet metalworking operations formability of sheet metalcupping test bulge test forminglimit diagramtension tests. Theoretical and experimental analysis of deep drawing. Cu and sn are used as lubricants for high strength materials. Defects in deep drawing selama proses deep drawing, gerakan kosong ke dalam rongga menginduksi tekanan melengkung tekan pada flens, yang cenderung menyebabkan flens berkerut saat ditekan. Index terms deep drawing, thickness, temperature, stress and strain, friction coefficient, blank holding force, strain. The deep drawing process involves a great deal of sliding of the sheet material along the tools. The aim of successful deep drawing process is to produce a product with greater final depth as well as with fewer defects. A brief description of such defects and their remedial method is given below. During drawing the volume remains the same and hence there is increased in the length of the drawn wire or rod. Apart from its use in many other sectors, it is applied in the automotive industry for the manufacturing of car body parts. It will be guidance for the practical production engineers engaged in this spinning area. The workpiece material used in a deep drawing process is anisotropic in nature, due to a prior thermomechanical treatment.
The effects of different variables, on the deep drawing process are discussed below. Overall dimensions of bgr shall be 8278h x 23w x 27d. To eliminate earing excessive deformation in deep drawing should be avoided. Deep drawing is a manufacturing process that is used extensively in the forming of sheet metal into cup or box like structures. Wrinkling of sheet metal material in deep drawing operations generally occur in the wall or flange of the part. Deep drawing dd is one of the sheet metal forming processes widely used in automobile. Deep drawing process is a significant metal forming process used in the sheet metal forming operations.
Rack shall be greenguard indoor air quality certified for children and schools. Predicting the behaviors of deformation during a forming process is one of. This paper also contains the comparative study of spinning and deep drawing process. Tears or cracks may occur when tubes are formed or deep drawn. The deep drawing of cylindrical cups has also been extensively studied see e. The aim of this section is to overview the current process for deep drawing of paperboard, materials which are used for it, and common defects and problems in deep drawing. In deep drawing process the main objectives are to obtain defect less or minimum defects in product. Rack shall be warrantied to be free from defects in material or workmanship under normal use and conditions for the lifetime of the product.
In deep drawing, one of the sheet metal forming processes is a widely used technique for producing parts from sheet metal blanks in a variety of fields such as aerospace and automobile. Pdf this paper shows the finite element simulation of the deep drawing process where. Otherwise, a good formability or product quality is related to proper part characteristics. Apr 15, 2017 sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. The prediction of these type of defects, as well as formability, are. The phenomenon of wrinkling flange instability is specific to the process of deepdrawing. Instability in the work piece, also called wrinkling of the walls. From this process complex shapes can be manufactured with fewer defects. Defects in axisymmetrically drawn bars caused by longitudinal superficial imperfections in the initial material. Large set of manufacturing processes in which the material is deformed plastically to take the. Sheet metal forming massachusetts institute of technology. Predicting the behaviors of deformation during a forming process is one of the main challenges in cold forming. The following is a list of common problems that may be encountered when deep drawing.
This thesis friction in deep dra wing considers some aspects of friction on the deep drawing process. Hydroforming cheap tooling, no net thinning, slowish, high formability low volume batches. Study on deep drawing process parameters jntuh college of. Stamping deep drawing fundamentals this course covers the fundamentals in sheet metal forming of steel, aluminum and highstrength steel, using practical examples from the automotive industry. Stateoftheart equipment allows precise sanding, filling and finish coverage of each of our products. Highquality server rack professional series from bud industries. This process is sometimes called drawing and is not. Applied for cylindrical cup manufacturing by multistage deep. Mar 14, 2012 defect in deep drawing slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Similarly rods are drawn from steel rounds of larger diameters. Effect of various parameters on the wrinkling in deep. Prediction of wrinkling is a very important process for a deep drawing operation.
Wrinkles can be prevented by using a blank holder, the. Pdf prediction of forming defects in deep drawing process. Finishing systems finishing systems the finishing systems used on our products are designed to ensure the beauty and durability of our cabinetry. Effects of different parameters on deep drawing process. Useable height of bgr shall be 45 rackspaces, useable depth shall be 24. Formability analysis of aluminum alloys through deep drawing process. 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. Effects of different parameters on deep drawing process ijert. Most common defects occurred during this process are wrinkle and tear. Effect of forming conditions on localized thinning in deep. 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. Pdf deep drawing is a sheet metal forming process which is widely used in manufacturing parts for automobile and air craft industries.
Reduction of wrinkling defect in deep drawing process. This article highlights only the most frequently violated design and build principles. What are the forging defects,causes and remedies defects in forging though forging process provides good quality products compared to other manufacturing processes, some defects that are lightly to come if proper care is not taken in forging process design. Drawing of wire from steel rod is a metal working process used for the reduction of the crosssection of the rod. 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. Jul, 2017 deep drawing along with its defects advantages disadvantages and application, deep, drawing, cup drawing, deep drawing force, deep drawing advantages, deep d. In sheetforming process, however, several types of failures could occur, such as rupturing, necking, wrinkling and spring back which is undesirable 2. Paper open access related content formability analysis of.
Numerous unconventional deep drawing techniques have recently been implemented that have helped increase the industrial uses of deep drawing. They cause defects in deep drawing such as surface and complete fractures, appearance defects, and shape inaccuracies. Effect of different lubricants on deep drawing of galvanized steel adnan i. This paper deals with the analysis of deep drawing of circular blanks into axisymmetric cylindrical cup using numerical modeling. Abstract this paper investigates the earing phenomenon in deep drawing of aa3105. Wrinkling usually occurs at the flange region by excessive compressive stresses leading to local buckling of the sheet. Earing is a defect that occurs due to uneven drawing as shown in figure. Deep drawing metal parts fabrication american aluminum. This process is used to manufacture small to midsized metal equipment. Therefore, it is important to optimize the process parameters to avoid defects in the parts and to minimize production cost. This paper aims to give an overview of the deep drawing of paperbased materials with the emphasis on the experienced deformations, on the role of mechanical properties of materials in deep drawing, and on the typical defects found in the shapes. Pdf finite element simulation of earing defect in deep. Slim 5 series rack shall be of readytoassemble construction. Deep drawing is the forming of smooth sheet blanks into hollow parts.
Pdf deep drawing mechanism, parameters, defects and. The article summarizes the defects in drawing and factors considered in press selection for drawing. Figureearing due to uneven drawing and part failure 3. Wire drawing process hot rolled rod pickling, descaling lubricating drawing\ remove scale causing surface defects. The deep drawing type of the forming process for paperboard is. Paper open access related content deep drawing mechanism. The four major defects which can occur during deep drawing are fracture, wrinkling, earing and spring back. Because a part wrinkled during the deep drawing process will not be accepted and most likely become as scrap. To reduce various defects in deep drawing process it is necessary to control some parameters of deep drawing process. The main defects of deep drawn parts are wrinkling andor necking. Defects in axisymmetrically drawn bars caused by longitudinal. Optimization of blank holder force to control wrinkling and fracture.
Failure of sheet metal parts during deep drawing processes usually takes place in the form of wrinkling or tearing. The deep drawing process, as one of the most applicable sheet metal forming process, is widely used in many industries. While these calculations can predict displacem ents, they cannot reveal the visual impact of the defect. Deep drawing deep drawing is one of the most widely used processes in sheet metal forming.
These defects can be seen around form ed areas within largely flat panels. Effect of various parameters on the wrinkling in deep drawing. 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. Figure 1a sheet metal deep drawing process depending upon several factors such as geometry, volume material type, deep drawing or stretch forming is used to form sheet metals. Fem simulation and ultimately the toolmakers experience, so that the defects of. Rack shall be rohs eu directive 200295ec compliant. Medraj mech 4216511 lecture 92 deep drawing sheet metal forming to make cupshaped, boxshaped, or other complexcurved. This study can help improve working conditions leading to defect free products. The main concern of the deep drawing industry is to optimize the various process parameters in order to get a complete deep drawn product with least defects. Nobody else manufactures a rotationally molded shock rack that is 30 deep and that fits inside the center portion of the case. Rack shall be manufactured by an iso 9001 and iso 14001 registered company. Effects of various parameters in deep drawing process over. Various literatures of research focus on parameters that affect most in deep drawing process.
Finite element simulation of earing defect in deep drawing. Pdf deep drawing mechanism, parameters, defects and recent. Jan 06, 2016 in these cases, problem solving can be enhanced by addressing common sources of deep drawing failures. On the other hand, necking is due to the excessive radial tensile stress. Marciniak the technical university of warsaw, poland. Some aspects of blankholder force schemes in deep drawing process. They have found optimum draw ratios in deep drawing 4. Skbs 30 inch deep rotomolded shock rack which should be an instant success with all companies utilizing the deeper servers such as the new dell and compaq. Manufacturing by multistage deep drawing with simultaneous ironing. Following is a list of common defects during sheet metal operation, with sketches are shown in figure 1. Sheet metal is drawn in either hydraulic or mechanical presses. Surface defects surface defects is an important issue in sheet metal stamping as the stamping process affects surface appearance and thus influences surface quality. In this process metal sheet is subjected to tensile and compressive stresses.
Pdf prediction of forming defects in deep drawing process by. The geometrical parameters have the following values. 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. Pots and pans for cooking, containers, sinks, automobile parts, such as panels and gas tanks, are among a few of the items manufactured by sheet metal deep drawing. Pdf deep drawing is a sheet metal forming process which is widely used in. Pots and pans for cooking, containers, sinks and automobile parts such as panels and gas tanks are among a few of the items manufactured by the steel sheet deep. Metal forming processes indian institute of technology. Oils and greases for wire drawing mulsifiable oils for wet wire drawing soap for dry drawing. Deep drawing process has different effectible process parameters from which an optimum level of. Mechanics of sheet metal forming college of engineering. We maintain a verticallyintegrated facility with onsite engineering, designing, and prototyping services. Deep drawing process is one of the most commonly used metal forming process within theindustrial field. This paper aims to provide an overview of the deep drawing process and the deformations experienced by paperbased materials in the deep drawing process. American aluminum company is a leading manufacturer of deep drawn parts, including cylinders, enclosures and irregular shapes.
Successful deep drawing is a combination of many important factors. In these cases, problem solving can be enhanced by addressing common sources of deep drawing failures. The flange of the blank undergoes radial drawing stress and tangential compressive stress during the stamping process, which sometimes results in wrinkles. Under certain conditions, this sliding will cause friction between the tools and the material. Prediction of earing in deep drawing of anisotropic aluminum alloy sheet using bbc2003 yield criterion s. The main focus of this course is on deep drawing of vehicle body parts. Study of earing defect during deep drawing process with. Detailed experimental and numerical analysis of a cylindrical. Or conversion coating such as sulphates or oxalates. Study of effect of various parameters on thinning tendency. Zaid abstract friction plays an important role in manufacturing some processes it is useful and required e.
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