Finite Element Simulation for Determining the Optimum Blank Shape for Deep Drawing Process

摘要

Deep drawing is one of widely used sheet metal working process in industries to produce cup shaped components at a very high rate. The present study aims to determine the optimum shape of blank for deep drawing of cylindrical cup without ears. Earing is one of the major defects observed during deep drawing process due to anisotropic nature of sheet metal. Earing is defined as formation of waviness on uppermost portion of deep drawn cup. Earing defect occurs due to non-uniform material properties within plane of sheet (i.e. planar anisotropy). Knowledge about ear formation in deep drawing process allows a prior modification of process which can result in defect free final product with financial saving and time. In the present study efforts have been made to study the earing problem in deep drawing of cylindrical cups by finite element modeling software HYPERWORK-6.12. The blank material as EN10130Fe01 mild steel sheet of 1mm thickness has been considered as it has wide application a fabricating critical automobile parts. Mechanical parameters of mild steel are incorporated in finite element simulation of deep drawing process. Significant earing was observed at rolling and transverse direction on deformed cup form circular blank. Modification of initial blank is done to find the optimum blank to reduce the earing defect. Optimal blank shows significant reduction of % earing height, reduction in drawing load & improvement in maximum thickness variations.