Analysis of axisymmetric cup forming of metal foil and micro. In deep drawing, as a first step, a cup is produced from the flat blank. Deep drawing is a common metal forming process used to manufacture recessed threedimensional parts from flat sheet metals. Introductionthe hydromechanical deep drawing hdd process has been used widely in the forming of complexshaped sheet metal parts 14. Presently, the cell case bottom part is deep drawn in 4 stages in conventional drawing process as shown in figure1.
Oct 18, 2018 micro hydromechanical deep drawing mhdd, a typical microforming method, has been developed to take advantage of hydraulic force. The hydromechanical forming tool may include a liquid chamber at the entrance to the draw chamber to reduce friction, as the blank is drawn into the draw chamber. Analysis of hydromechanical deep drawing and the effects. An numerical investigation on the control of process parameters for the hydromechanical deep drawing with special attention to control of the blank holder force bhf is carried out. Warm hmd process was carried out on a warm sheet hydroforming experiment platform to investigate the influences of key processing parameters on formability. Heated hydromechanical deep drawing of magnesium sheet. The effect of the counter pressure in the hydromechanical deep. Cylindrical cup hydromechanical deep drawing hmd at elevated temperature is the typical process for basic research. A numerical model was established to investigate the micro hydromechanical deep drawing process of austenitic stainless steel 304 foil 0. Due to the miniaturisation of the specimen size, the effect of grain size, gap distance and radial pressure during drawing process could be prominent.
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. Pdf effect of mechanical properties on deep drawing. With this process components can be manufactured in a single step, as opposed to conventional deep drawing, which either requires several steps or, due. Pdf optimization of the geometrical parameters for.
Whdd process combines the advantages of hydromechanical deep drawing hdd and warm deep drawing wdd processes. An investigation of the effect of temperature variability. Differences in strains obtained for the conventional and hydromechanical deep drawing process as well as process limitations are presented. Gupta ak, singh sk, swathi m, gokul h 2012 prediction of flow stress in. Hydromechanical deep drawing hdd, as a combination of conventional deep drawing with sheet hydroforming, has been widely used in the forming of complexshaped sheet materials 7. The hydromechanical deep drawing process of aluminum cups and mild steel cups is analyzed experimentally and numerically. Hydroforming is a costeffective way of shaping ductile metals such as aluminium, brass, low alloy steel, and stainless steel into lightweight, structurally stiff and strong pieces. In this paper the hydromechanical deep drawing and the effect of friction in the process has been studied using fe method.
Forthisreason, theparametersaectingtheprocessaretemperatureand. They found that flow stress of the bilayer sheet followed the rule of mixture. Sheet metal forming processes ksu college of engineering ie department 3 definition. Investigation of friction effect in limit drawing ratio. Punchworkpiece and dieworkpiece friction coefficients together with the initial gap between the blank holder and matrix were considered as the process variables which, in optimization terminology, are called design parameters. In the present paper a feasibility study of a funerary vase, made of stainless steel, using the hydromechanical deep drawing process, is presented. Warm hydromechanical deep drawing whdd is considered as an effective sheet metal forming process to overcome low formability problems of lightweight materials, such as aluminum and magnesium alloys, at room temperature. Deep drawing is a common process in industry for manufacturing products from sheet metals. The process windows for each process have been established based on the analyzed parameters of the three different product geometries. Deep drawing mechanism, parameters, defects and recent results. Deep drawing is an important process used for producing cups from sheet metal in large quantities.
A study on doe methods for hydromechanical deep drawing process. In the hydromechanical deep drawing process, the fluid pressure is used for postponing the fracture occurrence in the blank, while the thtb technique allows to create a material property gradient through a suitable a. May 02, 2015 as an alternate and efficient strategy, simultaneous forming of multiple blanks has been studied by using hydromechanical deep drawing hdd method. Comparison of conventional deep drawing, hydromechanical. To verify the results of fe simulations, an experimental study has been used in a specific friction condition. The process is widely used for producing different products such as automotive parts, cans, sinks and housing, and.
Pdf numerical optimization of warm hydromechanical deep. One of the largest applications of hydroforming is the automotive industry, which makes use of the complex shapes made possible by hydroforming to produce stronger, lighter, and more rigid unibody structures for. The experimental investigation of effects of multiple parameters on. Jan 16, 2012 cylindrical cup hydromechanical deep drawing hmd at elevated temperature is the typical process for basic research. Pdf investigation of hydrodynamic deep drawing for conical. Numerical simulation conducted by finite element method is one of the most powerful tools for analyzing metal forming processes. The main aim of any unconventional deep drawing process is to extend the formability limits of the process. Higher economic efficiency and flexibility can be achieved by using hdd process. Pdf warm hydromechanical deep drawing of aa 5754o and. Abstract the application of hydro mechanical deep drawing hmdd process on laminated sheets combines advantages of both process and material to improve the forming condition of poor formable lightweight metals such as aluminum alloys. Pdf numerical model for the oil pressure distribution in. The hydromechanical deep drawing hmdd process has become an emerging.
An investigation on the effects of optimum forming parameters. The effects of the parameters on the limit drawing ratio were numerically examined and compared experimentally using ansys packaged. Hydromechanical deep drawing process have being implemented as a modern manufacturing technology in sheet metal industry for last decades with the advantages of. Paper open access related content deep drawing mechanism. Moreover, the, zhang 1998 drawing ratio in the hydromechanical deep drawing r is highe than that inconventional deep drawing due to several the fracture restraint effects, nakamura 1984. Introductionin the hydromechanical deep drawing process hdd the cup is drawn into a. For large parts, explosive hydroforming can generate the forming pressure by simply exploding a charge above the part complete with evacuated mold which is immersed in a pool of water. The hydro mechanical deep drawing process is forming using liquid pressure.
Determination of process parameters in multistage hydro. In this paper a numerical study of hdd of a can box is presented. Model development and process parameters investigation e. Pdf warm hydromechanical deep drawing whdd is considered as an effective sheet metal forming process to overcome low formability problems of. Pdf study on micro hydromechanical deep drawing using finite. Hydromechanical deep drawing process have being implemented as a modern manufacturing technology in sheet metal industry for last decades with the advantages of reduced tooling costs, increased. Drawing and high pressure sheet metal forming by numerical experiments. Sorry, we are unable to provide the full text but you may find it at the following locations. Among them, hydromechanical deep drawing hdd is, probably, the process which has gained the major interest in industries in the last few years.
Sheet metal hydromechanical deep drawing process optimization. The experimental investigation of effects of multiple. Very complex parts can be achieved using deep drawing. The schematic drawing of the conventional deep drawing process is depicted in figure 6. Ifu stuttgart alu training in aluminium application technologies hydromechanical deep drawing 3704. This cup can then be further processed, for example by an additional drawing, reverse drawing, ironing or extrusion process. Theoretical study on hydromechanical deep drawing process of. Formability of sheet metals can be increased by hydromechanical deep drawing hdd process. Ep0590262a1 explosion assisted hydromechanical deep. The hydromechanical deep drawing process has been developed as the radial hydromechanical deep drawing hydrorim process figure 4b. The breakage prediction for hydromechanical deep drawing. Volume 212, issue 9, september 2012, pages 18401849. The application of hydroforming process on aluminumsteel laminated sheets includes advantages of both process and material to improve formability of lightweight low formable aluminum sheets.
Journal of computational applied mechanics, 49, 1, 2018, 5462. Arranging of the process parameters requires a great knowledge. Pdf deep drawing is an important process used for producing cups from sheet. Microhydromechanical deep drawing of metal cups with. This pressure forces the blank against the punch, which results in a close contact between blank and punch. Figure 37 effect of n thickness to grain size ratio on material flow stress. Also, the effect of process variables such as cavity pressure and blank holding force bhf and their role in wrinkles formation, thinning, edges movement and formability for the hdd process. Hydromechanical deep drawing forming of flat sheets alongside internal highpressure forming, hydromechanical deep drawing is also continually gaining in significance. The present research work is concerned with the effects of optimum process variables in elevated temperature hydro mechanical deep drawing of 5052 aluminum alloy. Sheet material st14 draw quality steel of thickness 1 mm was used for this study. Developments in sheet hydroforming for complex industrial parts.
Theoretical study on hydromechanical deep drawing process of bimetallic sheets and experimental observations september 2012 journal of materials processing technology 2129. Bortotd university of brescia, department of mechanical engineering, via branze 38, 25123 brescia, italy. The tooling can be much cheaper than what would be required for any press. Theoretical study on hydromechanical deep drawing process. An investigation on the effects of optimum forming. Finite element analysis of fluidstructure interaction in. Deep drawing process is a simple nonsteady state metal forming process, it is widely used in industry for making seamless shells, cups and boxes of various shapes. Finite element analysis of fluidstructure interaction in the.
With reduced dimensions, the hydraulic pressure development changes. A hydromechanical forming tool is disclosed that may include electrohydraulic forming chambers in which a stored charge circuit may be discharged through electrodes to improve the level of detail that may be formed in a blank. Hydromechanical deep drawing is a capable process for producing complicated and taperedshaped stamping parts as well as parts which require excellent surface quality, i. Comparison of conventional deep drawing, hydromechanical deep. Pdf finite element analysis of the hydromechanical deep. The hydrodynamic flow is calculated by solving the reynolds equation.
Some of the unconventional processes include hydromechanical deep drawing, hydroform process, aquadraw process, guerin process, marform process and the hydraulic deep drawing process to name a few. It will further show how the process parameters temperature and fluid pressure influence the deep drawing process. Hydromechanical deep drawing damborg 2000 scandinavian. A study on doe methods for hydromechanical deep drawing. Among these, determination of safe fluid pressure to preclude rupture instability in each layer of bimetallic sheets in hmdd process is important. The main defects of deep drawn parts are wrinkling andor necking. The hydromechanical deep drawing process of a cylindrical cup part was simulated using the commercial software abaqus implicit.
Pdf a study on doe methods for hydromechanical deep. In the first part of the current study, whdd of aa 5754o was studied. To investigate the part feasibility, several fe simulations were implemented using the aquadraw tool of the explicit fe. Pdf a study on doe methods for hydromechanical deep drawing. It is essential to analyze the hdd process of cylindrical cups with the nite element method 59, so that many fundamental process phenomena such as prebulging deformation, thinning and wrinkling can be analyzed and predicted without the need of many. Numerical optimization of warm hydromechanical deep. Theoretical study on hydro mechanical deep drawing process of bimetallic sheets and experimental observations. Investigation of hydrostatic counter pressure effect on. In order to obtain the highest formability, an optimization study was performed for aa 5754o whdd process parameters tool temperature. The onset of the breakage of the part during the forming process was predicted by combining the simulation results with the local necking criterion. Deep drawing is a sheet metal forming process which is widely used in.
Analysis of hydromechanical deep drawing and the effects of. Warm hydromechanical deep drawing whdd has increasingly been implemented by automotive industry due to its various benefits including mass reduction opportunities in auto bodyinwhite components and improved formability for lightweight alloys. Formability of the deep drawn cups is generally assessed by limiting drawing ratio ldr which is the ratio of the blank diameter to punch diameter. An investigation of the effect of temperature variability of. Hydromechanical deep drawing, geerts deep drawing and re. Langb a department of production, aalborg university, fibigerstraede 16, dk9220 aalborg, denmark b school of materials science and engineering, harbin institute of technology. Femprocess simulations of hydromechanical deepdrawing. The liquid will be pressurized and will push the blank tightly on the punch surface. Abstract the present work demonstrates the effectiveness of combining the hydromechanical deep drawing process with the tailored heat treated blank thtb technique. Number of production stage can be reduced to one stage by using hdd method, for example one draw is sufficient to form a hemispherical part in the hdd process, where as five draws and a. Analysis of axisymmetric cup forming of metal foil and. The research in deep drawing has been generic over the last few decades and various aspects of this process have been investigated. An investigation on the effects of optimum forming parameters in hydromechanical deep drawing process using the genetic algorithm.
This study focuses on the assessment of sheet hydroforming, hydro. Experimental investigation on hydromechanical deep drawing. Numerical and experimental investigations of hydro. Hydromechanical deep drawing of cups with stepped geometries. The draw chamber may have a movable bottom wall that is moved in tandem with the punch to reduce the amount of liquid in the draw chamber and reduce the need to pump liquid into and. Numerical optimization of warm hydromechanical deep drawing. Experimental investigation on hydromechanical deep drawing of. In hydromechanical deep drawing, the process is assisted by a. Prevent of wrinkling and rupturing using a new method based. Us9375775b2 hydromechanical drawing process and machine. Pdf theoretical study on hydromechanical deep drawing.
In this work, we attempt to explain the lubrication mechanisms at the blankdie contact zone during the hydromechanical deep drawing process and to simulate such process. The effects of the process parameters on the final product quality are. Part quality and thickness distribution obtain by using hydromechanical deep drawing process is also better than conventional deep drawing process. Inthisprocess,thesheetisformedbystretching itafteritwasclampedbyblankholder3. Pdf analysis of the hydromechanical deep drawing of. Pdf a numerical model was established to investigate the micro hydro mechanical deep drawing process of austenitic stainless steel 304 foil. In this research, the hmdd process of anisotropic laminated bimetallic sheets has been analyzed using a 3d finite element simulation with implementing. Ep0590262a1 explosion assisted hydromechanical deep drawing.
In order to increase ldr by hdd, process parameters of the hdd should be arranged properly. Comparative study of warm and hydromechanical deep drawing for. Onder and tekkaya worked to determinate the optimum sheet metalforming process. In this research, analytical models were developed to investigate stress analysis and instability condition in hydromechanical deep drawing hmdd of. Hydromechanical deep drawing process is an efficient method for production of complicated parts. Thesheetisheatedtoacertaintemperatureandthen pressedintothediewithahotuidinwarmhydroforming withdie. Chapter two aspects of deep drawing and microscale. Journal of materials processing technology 102 2000 18 finite element analysis of the hydromechanical deep drawing process of tapered rectangular boxes s.
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