Experimental and Analytical Investigation of Deep Drawing Process for producing Pentacle Cups
Received: 15 February 2024 | Revised: 26 February 2024 and 2 March 2024 | Accepted: 6 March 2024 | Online: 1 June 2024
Corresponding author: Zainab H. Mohsein
Abstract
Sheet metal forming is a critical process in modern manufacturing, used to create both finished and semi-finished products. In this industry, there is an increasing demand for fast and cost-effective manufacturing and modification of dies. Therefore, improving theoretical and experimental engineering approaches to reduce manufacturing costs and lead-time between design and production is essential. The development of numerical methods has made Finite Element Analysis (FEA) a valuable tool for predicting product deformation. This study used three forming methods to create a pentacle cup from a low-carbon steel sheet (1008-AISI) with a thickness of 0.7 mm and a diameter of 80 mm. ANSYS Workbench 3-D modeling software was utilized to simulate the drawing procedures. The resulting product's wall thickness and strain were measured and graphed to demonstrate the impact of the different forming methods. The first method involved direct formation by drawing a circular blank metal into a pentacle shape. The second method involved redrawing a cylindrical cup into a pentagonal cup, while the third method entailed converting a pentagonal cup into a pentacle cup. The results showed that the second forming method produced the highest maximum punch load reaching approximately 42.24 kN in experimental testing and 36.66 kN in Finite Element Modeling (FEM), exceeding that of the third forming method. The maximum thinning at cup curvature was observed in the pentacle cup created by the second method, particularly in the major and minor areas, and was more pronounced than in the pentacle cups produced by the third forming method. Ultimately, the third forming method was identified as the optimal technique for producing a pentacle cup with less thinning at the cup curvature and a more uniform distribution of thickness and strain. Overall, this study highlights the importance of advancements in theoretical and experimental engineering approaches to reduce manufacturing costs and improve the efficiency of the sheet metal forming process. The findings from this study can lead to the development of optimal forming techniques for creating high-quality products.
Keywords:
pentagonal cup, direct method, convert method, FEM, pentacle cupDownloads
References
J. Jeswiet et al., "Metal forming progress since 2000," CIRP Journal of Manufacturing Science and Technology, vol. 1, no. 1, pp. 2–17, Jan. 2008. DOI: https://doi.org/10.1016/j.cirpj.2008.06.005
D. Janardhan, "Determination and optimisation of cylindrical grinding process parameters using Taguchi method and regression Analysis," International Journal of Engineering Science and Technology, vol. 3, pp. 5659–5665, Jul. 2011.
S. Reddy, S. Rajesham, R. R. Pinninti, and A. C S Reddy, "Evaluation of Limiting Drawing Ratio (LDR) in Deep Drawing by Rapid Determination Method," International Journal of Current Engineering and Technology, vol. 4, no. 2, pp. 757–762, Apr. 2014.
K. Roll, "Simulation of sheet metal forming-necessary development in the future," in LS-DYNA Anwenderforum, German, 2008, pp. 59–68.
J. Sutherland et al., "A global perspective on the environmental challenges facing the automotive industry: State-of-the-art and directions for the future," International Journal of Vehicle Design, vol. 35, no. 1–2, pp. 86–110, Jan. 2004. DOI: https://doi.org/10.1504/IJVD.2004.004050
N. S. M. Namer, S. A. Nama, and J. W. Thabit, "Numerical and Experimental Study on Deep Drawing Process for AA2024-T4 Sheet," Journal of Applied and Experimental Mechanics, vol. 1, no. 1, pp. 1–9, 2015.
P. V. R. R. Reddy, B. V. S. Rao, G. C. M. Reddy, and P. R. Prasad, "Parametric Studies on Wrinkling and Fracture Limits in Deep Drawing of Cylindrical Cup," International Journal of Emerging Technology and Advanced Engineering, vol. 2, no. 6, pp. 218–222, 2012.
M. El Sherbiny, H. Zein, M. Abd-Rabou, and M. El shazly, "Thinning and residual stresses of sheet metal in the deep drawing process," Materials & Design, vol. 55, pp. 869–879, Mar. 2014. DOI: https://doi.org/10.1016/j.matdes.2013.10.055
S. Candra, I. M. L. Batan, W. Berata, and A. S. Pramono, "Analytical Study and FEM Simulation of the Maximum Varying Blank Holder Force to Prevent Cracking on Cylindrical Cup Deep Drawing," Procedia CIRP, vol. 26, pp. 548–553, Jan. 2015. DOI: https://doi.org/10.1016/j.procir.2014.08.018
U. Pranavi, P. J. Ramulu, C. Chandramouli, D. Govardhan, and P. R. Prasad, "Formability analysis of aluminum alloys through deep drawing process," IOP Conference Series: Materials Science and Engineering, vol. 149, no. 1, Jun. 2016, Art. no. 012025. DOI: https://doi.org/10.1088/1757-899X/149/1/012025
R. Dwivedi and G. Agnihotri, "Study of Deep Drawing Process Parameters," Materials Today: Proceedings, vol. 4, no. 2, Part A, pp. 820–826, Jan. 2017. DOI: https://doi.org/10.1016/j.matpr.2017.01.091
B. Mulyanto and D. S. Khaerudini, "Simulation and Experimental Investigation of Wrinkle Defect in Deep Drawing Process of Carbon Steel Spcc Shaped Cylinder Flange Cup," Sinergi, vol. 24, no. 3, pp. 197–206, 2020. DOI: https://doi.org/10.22441/sinergi.2020.3.004
A. K. Choubey and C. Sasikumar, "Effect of Anisotropy, Temperature, Strain Rate on Deep Drawing Using Conical Die," Journal of Metallic Material Research, vol. 3, no. 1, pp. 20–24, Apr. 2020. DOI: https://doi.org/10.30564/jmmr.v3i1.920
Y. Harada, Y. Nishikubo, and I. Tanaka, "Drawability of Functional Corrugate Cup Using Roller Die," Materials Transactions, vol. 61, no. 2, pp. 222–227, 2020. DOI: https://doi.org/10.2320/matertrans.MT-ML2019004
S. Pandre, N. Kotkunde, A. Morchhale, S. K. Singh, and A. Saxena, "Comparative study of formability characteristics in deep drawing of DP 590 steel using analytical models," Advances in Materials and Processing Technologies, vol. 8, no. sup3, pp. 1730–1740, Oct. 2022. DOI: https://doi.org/10.1080/2374068X.2021.1945273
W. Rajhi, "Numerical Simulation of Damage on Warm Deep Drawing of Al 6061-T6 Aluminium Alloy," Engineering, Technology & Applied Science Research, vol. 9, no. 5, pp. 4830–4834, Oct. 2019. DOI: https://doi.org/10.48084/etasr.3148
S. L. Semiatin, ASM Handbook, Volume 14B: Metalworking: Sheet Forming. Almere, Netherlands: A S M International, 2006. DOI: https://doi.org/10.31399/asm.hb.v14b.9781627081863
"Home," ASM International. https://www.asminternational.org/.
W. Jawad and A. Ikal, "Effect of Radial Clearance on Stress and Strain Distribution in the Astral Deep Drawing," Engineering and Technology Journal, vol. 37, no. 8A, pp. 332–340, Aug. 2019. DOI: https://doi.org/10.30684/etj.37.8A.4
Schuler, Metal Forming Handbook. Berlin, Germany: Springer, 1998.
D. Ravi Kumar, "Formability analysis of extra-deep drawing steel," Journal of Materials Processing Technology, vol. 130–131, pp. 31–41, Dec. 2002. DOI: https://doi.org/10.1016/S0924-0136(02)00789-6
W. Rajhi, B. Ayadi, A. Alghamdi, and N. Messaoudene, "An Anisotropic Elastic-plastic Model for the Optimization of a Press Machine’s Auxiliary Worktable Plate Thickness," Engineering, Technology & Applied Science Research, vol. 8, no. 2, pp. 2764–2769, Apr. 2018. DOI: https://doi.org/10.48084/etasr.1934
W. Khalid Jawed and S. Salman Dawood, "Drawing of Hexagonal Shapes from Cylindrical Cups," Engineering and Technology Journal, vol. 34, no. 6A, pp. 1235–1246, Jun. 2016. DOI: https://doi.org/10.30684/etj.34.7A.16
M. J. Jweeg, A. I. Mohammed, and M. S. Jabbar, "Investigation of Thickness Distribution Variation in Deep Drawing of Conical Steel Products," Engineering and Technology Journal, vol. 39, no. 4A, pp. 586–598, Apr. 2021. DOI: https://doi.org/10.30684/etj.v39i4A.1908
J. Hu, Z. Marciniak, and J. Duncan, Mechanics of Sheet Metal Forming. Oxford, UK: Butterworth-Heinemann, 2002.
W. F. Hosford and R. M. Caddell, Metal Forming: Mechanics and Metallurgy, 3rd edition. Cambridge, MA, USA: Cambridge University Press, 2007. DOI: https://doi.org/10.1017/CBO9780511811111
A. Rastbood, Y. Gholipour, and A. Majdi, "Finite Element Based Response Surface Methodology to Optimize Segmental Tunnel Lining," Engineering, Technology & Applied Science Research, vol. 7, no. 2, pp. 1504–1514, Apr. 2017. DOI: https://doi.org/10.48084/etasr.1045
E. A. Abbas and K. K. Mansor, "Numerical and Experimental Investigation of the Effect of Strength of Aluminum 6061 Alloy on Thickness Reduction in Single-Point Incremental Forming," Advances in Science and Technology. Research Journal, vol. 17, no. 4, pp. 271–281, Aug. 2023. DOI: https://doi.org/10.12913/22998624/170713
A. S. Bedan, A. H. Shabeeb, and E. A. Hussein, "Improve Single Point Incremental Forming Process Performance Using Primary Stretching Forming Process," Advances in Science and Technology. Research Journal, vol. 17, no. 5, pp. 260–268, Oct. 2023. DOI: https://doi.org/10.12913/22998624/172907
Downloads
How to Cite
License
Copyright (c) 2024 Zainab H. Mohsein, Waleed K. Jawad, Aseel H. Abed
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.
