Experimental and finite element investigation on wrinkling of circular single layer and two-layer sheet metals in deep drawing process

  • Mohammad Reza Morovvati
  • Afshin Fatemi
  • Mojtaba Sadighi
ORIGINAL ARTICLE
First Online:
Received:
Accepted:

Abstract

This paper deals with the comparison of wrinkling behavior of both single and two-layer sheets in the deep drawing process. Unfortunately, due to the significant difference in the material properties of the two layers, it is very challenging for the finite element method to predict the location and relative possibility of wrinkling in the multilayer sheets. Blank holder force (BHF) has a significant effect on the failure mode of sheet metals. By decreasing BHF, wrinkling turns out as the principal failure mode, whereas its increase results in splitting and fracture. Thus, this paper investigates the effect of blank holder forces on wrinkling and fractures in drawing process of single and two layers. Moreover, the effect of material and arrangement of layers on wrinkling, fracture, and required deformation forces in the cylindrical deep drawing will be discussed. Results show that the optimum blank holder force for two-layer sheets is affected by the material and arrangements of lay-ups.

Keywords

Two-layer sheet Wrinkling Fracture Deep drawing FEM BHF 
This is a preview of subscription content, log in to check access.

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Yoshida F (1997) Deformation and fracture of sheet metal laminates in plastic forming. Proceedings of 4th international conference on composite engineering, pp 61–64Google Scholar
  2. 2.
    Hwang YM, Hsu HH, Lee HJ (1995) Analysis of sandwich sheet rolling by stream function method. Int J Mech Sci 37(3):297–315MATHCrossRefGoogle Scholar
  3. 3.
    Senior BW (1956) Flange wrinkling in deep-drawing operations. J Mech Phys Solids 4:235–246CrossRefGoogle Scholar
  4. 4.
    Triantafyllidis NA, Needleman (1980) An analysis of wrinkling in the swift cup test. ASME J Eng Mater Technol 102:241–248CrossRefGoogle Scholar
  5. 5.
    Yu TX, Johnson W (1982) The buckling of annular plates in relation to the deep drawing process. Int J Mech Sci 24:175–188MATHCrossRefGoogle Scholar
  6. 6.
    Améziane-Hassani H, Neale KW (1991) On the analysis of sheet metal wrinkling. Int J Mech Sci 33:14–30Google Scholar
  7. 7.
    Yang DY, Lee HS (1991) An analysis of hemispherical punch stretching by the energy method. Int J Mech Sci 33:435CrossRefGoogle Scholar
  8. 8.
    Sukhomlinov LG, Engelsberg VK, Davgdov VN (1992) A finite element membrane model for the analysis of axisymmetric sheet metal forming processes. Int J Mech Sci 34:179–193MATHCrossRefGoogle Scholar
  9. 9.
    Kampus Z, Kuzman K (1992) Experimental and numerical (FEM) analysis of deep drawing of relatively thick sheet metal. J Mater Process Technol 34:133–140CrossRefGoogle Scholar
  10. 10.
    Wang CH, Kinzel G, Altan T (1994) Wrinkling criterion for an anisotropic shell with compound curvatures in sheet forming. Int J Mech Sci 36:945–960MATHCrossRefGoogle Scholar
  11. 11.
    Mori T, Kurimoto S (1996) Press-formability of stainless steel and aluminum clad sheet. J Mater Process Technol 56:242–253CrossRefGoogle Scholar
  12. 12.
    Zeng XM, Mahdavian SM (1998) Critical conditions of wrinkling in deep drawing at elevated temperature. J Mater Process Technol 84:38–46CrossRefGoogle Scholar
  13. 13.
    Parsa MH, Yamaguchi K, Takahura N (2001) Redrawing analysis of aluminum-stainless steel laminate sheet using FEM simulations and experiments. Int J Mech Sci 43:2331–2347MATHCrossRefGoogle Scholar
  14. 14.
    Cao J, Wang X, Mills FA (2002) Characterization of sheet buckling phenomenon subjected to controlled boundary constraints. ASME J Manuf Sci Eng 124(8):493–501CrossRefGoogle Scholar
  15. 15.
    Cheng HS, Cao J, Yao H, Liu SD, Kinsey B (2004) Wrinkling behavior of laminated steel sheets. J Mater Process Technol 151:133–140CrossRefGoogle Scholar
  16. 16.
    Gresham J, Cantwell W, Cardew-Hall MJ, Compston P, Kalyanasundaram S (2006) Drawing behaviour of metal–composite sandwich structures. Compos Struct 75:305–312CrossRefGoogle Scholar
  17. 17.
    Padmanabhan R, Baptista AJ, Oliveira MC, Menezes LF (2007) Effect of anisotropy on the deep-drawing of mild steel and dual-phase steel tailor-welded blanks. J Mater Process Technol 184:288–293CrossRefGoogle Scholar
  18. 18.
    Lin H, Wang J, Long AC, Clifford MJ, Harrison P (2007) Predictive modeling for optimization of textile composite forming. Compos Sci Technol 67:3242–3252CrossRefGoogle Scholar
  19. 19.
    Narayanasamy R, Loganathan C (2008) Study on wrinkling limit of interstitial free steel sheets of different thickness when drawn through conical and tractrix dies. Mater Des 29:1401–1411CrossRefGoogle Scholar
  20. 20.
    Demirci HI, Esner C, Yasar M (2008) Effect of the blank holder force on drawing of aluminum alloy square cup: theoretical and experimental investigation. J Mater Process Technol 206:152–160CrossRefGoogle Scholar
  21. 21.
    Jalali Aghchai H, Shakeri M, Mollaei-Dariani B (2008) Theoretical and experimental formability study of two-layer metallic sheet (Al1100/St12). Proc IMechE Part B J Engineering Manufacture JEM 1140(222):1131–1138CrossRefGoogle Scholar
  22. 22.
    Chen L, Yang JC, Zhang LW, Yuan SY (2007) Finite element simulation and model optimization of blank holder gap and shell element type in the stamping of a washing-trough. J Mater Process Technol 182:637–643CrossRefGoogle Scholar
  23. 23.
    Lang L, Danckert J, Nielsen KB (2005) Multi-layer sheet hydro forming: experimental and numerical investigation into the very thin layer in the middle. J Mater Process Technol 170:524–535CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Limited 2010

Authors and Affiliations

  • Mohammad Reza Morovvati
    • 1
  • Afshin Fatemi
    • 1
  • Mojtaba Sadighi
    • 1
  1. 1.Mechanical Engineering DepartmentAmirkabir University of TechnologyTehranIran

Personalised recommendations