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Experimental and numerical investigation to determine the optimal blank-holder force in deep drawing process based on forming force for SS304L and St14 sheets

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Abstract

Blank holder force (BHF) is one of the important process parameters in the deep drawing process. BHF helps produce defect-free components by controlling metal flow during the deep drawing process. If BHF is low, it causes wrinkling; otherwise, it causes the sheet to rupture. Therefore, optimization of BHF is an important issue in industries. One of the effective approaches to determining optimal BHF is to study forming force, thickness distribution, and wrinkles to produce a deep-drawn cup. The main function of this approach is that it minimizes the maximum forming force and prevents process limits. Therefore, this study aims to investigate the relationship between the BHF and forming force through experimental and simulation results. In addition, the effect of BHF on the thickness distribution and wrinkling is considered. Hence, numerical and experimental methods were employed for St14 and SS304L sheets with thicknesses of 0.5, 1, and 1.5 mm to achieve the objectives. Firstly, the simulation of the process was performed to study the mechanical behavior. Then, a set of experimental tests were conducted to validate the simulations. Finally, utilizing the experimental and numerical results, the optimal BHF value was determined. It was observed that the maximum thinning and maximum forming force are related to the forming process without BHF. Moreover, when the wrinkling at the edge of the part was removed by gradually increasing BHF, the minimum values of forming force and thinning were obtained. According to the investigations carried out on three thicknesses, it was observed that by reducing the thickness from 1.5 to 0.5 mm, the maximum forming force decreases in both SS304L and St14 sheets. However, the acquired results showed that the minimum optimal BHF is obtained in both sheets at a thickness of 1.5 mm. Overall, this research provides valuable experimental and numerical guidance for implementing the deep drawing process to manufacture cylindrical parts with minimum forming force required to save energy consumption.

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Funding

The authors declare that no funds, grants, or other support were received during the preparation of this manuscript.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Advanced Material Forming Research Center, Babol Noshirvani University of Technology, P.O. Box 484, Babol, Mazandaran, Iran

    Aliakbar Asgharpour & Hamid Gorji

  2. Department of Mechanical Engineering, Islamic Azad University- Sari Branch, Sari, Iran

    Seyed Ehsan Delpazir

Authors
  1. Aliakbar Asgharpour
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  2. Hamid Gorji
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  3. Seyed Ehsan Delpazir
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by Aliakbar Asgharpour, and prof. Hamid Gorji. The first draft of the manuscript was written by Aliakbar Asgharpour and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Hamid Gorji.

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Technical Editor: Diego Carou Porto.

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Asgharpour, A., Gorji, H. & Delpazir, S.E. Experimental and numerical investigation to determine the optimal blank-holder force in deep drawing process based on forming force for SS304L and St14 sheets. J Braz. Soc. Mech. Sci. Eng. 46, 349 (2024). https://doi.org/10.1007/s40430-024-04935-6

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