Influence of process parameters on residual stresses in deep-drawing process with FEM and experimental evaluations

Technical Paper

Abstract

This paper presents experimental and simulation study to minimize residual stress in cylindrical deep-drawing process. Eight significant process parameters including initial blank thickness, punch and die shoulder radii, blank–holder force, punch velocity, and coefficients of friction between die–blank, holder–blank, and punch–blank are considered. According to number of parameters, the Taguchi’s method is employed to perform design of experiments. The die is designed and manufactured, and the experiments are carried out using AISI 1006 carbon steel sheet. Hole-drilling method based on ASTM E 837-99 standard is applied to measure the residual stresses in drawn cups. Moreover, the deep-drawing process is simulated wholly using ABAQUS/explicit software and the accuracy of finite-element model is verified using experimental results. Finally, the analysis of variance method is applied to define the most important parameters and obtain an optimum level to minimize the residual stress in cylindrical deep-drawing process.

Keywords

Deep-drawing Residual stress Taguchi method Optimization Finite-element method Experiments 

List of symbols

BHF

Blank–holder force (KN)

rd

Die shoulder radius (mm)

rp

Punch shoulder radius (mm)

µd

Coefficient of friction between die and blank

µh

Coefficient of friction between holder and blank

µp

Coefficient of friction between punch and blank

Notes

Acknowledgements

The authors are grateful for the research support of the Iran National Science Foundation (INSF).

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Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  1. 1.Department of Mechanical and Aerospace EngineeringIslamic Azad University, Science and Research BranchTehranIran
  2. 2.School of Mechanical Engineering, College of EngineeringUniversity of TehranTehranIran

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