Deep drawing of cup shaped steel component: finite element analysis and experimental validation

ABSTRACT: The deep drawing process is one of the important sheet metal forming process. In this paper, different methods of analysis such as analytical, numerical and experimental techniques are employed to determine sheet blank size, formability and thickness distribution. The traditional sheet plate forming techniques used in industry is experimental, expansive and time consuming methods. Prediction of the formability, thickness distribution in deep drawing process will decrease the production cost and time of material to be formed. With this regard, the numerical simulations were conducted using the finite element method for cup shaped components with flange. Thickness distribution is obtained for entire cup along with flange. The results obtained from this numerical analysis are compared with experimental findings and results of other researchers. Experimentally thickness distribution is obtained by measurement at various locations in half cut cup along with flange region. Also analytical relationship is suggested to obtain correct initial blank size for cup shaped components with flange on the basis of principal of constancy of volume. As a result of this, 90-95 % consistency is obtained between the finite element result and experimental, analytical findings for initial blank size, formability and thickness distribution. Analytical models are extensive and experimentation is time consuming and expensive. Thus one can rely on FEA and simulations can be carried out to control IBS, formability, thickness distribution for component of same family by taking initial guess of IBS from analytical formula to avoid time and cost in field trials by controlling parameters of tooling and press machine