Skip to main content
SpringerLink
Log in

The Investigation and Optimization of Process Parameters in Warm Deep Drawing of ASS304 Steel Using Box Behnken Design and Applying Temperature Gradient

  • Published:
Experimental Techniques Aims and scope Submit manuscript

Abstract

Warm deep drawing of high specific strength materials has attracted more attention in automotive and aerospace industries. Optimization of process parameters is a very important task in deep drawing process to reduce the production costs. In this paper, four process parameters, namely temperature, blank holder force, punch corner radius and matrix cavity corner radius have been planned and utilized according to the Box-Behnken design of response surface methodology in gradient warm deep drawing process. Their effects have been investigated on thickness distribution limiting drawing ratio and maximum forming force at ambient temperature up to 300 °C on an austenitic stainless steel 304 sheet. The optimum setting of mentioned factors has been reported to minimize an objective function response targets individually and simultaneously. Results show that the optimum setting to simultaneously satisfy the response targets includes the blank holder force of about 2200 N, a punch corner radius equal to 7.5 mm, a matrix cavity corner radius near 5 mm and a temperature of about 160 °C.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Neugebauer R, Bräunlich H (1999) Lightweight construction by innovative forming technologies. Proceedings of the Sixth International Conference on Technology of Plasticity, Nuremberg (24) pp. 1119–1128

  2. Hakimian H, Sedighi M, Asgari A (2016) Experimental and numerical study on the ECARed magnesium AZ31 alloy. Mechanics & Industry 17:110

    Article  Google Scholar 

  3. Polmear I, StJohn D, Nie J-F, Qian M (2017) Light alloys: metallurgy of the light metals, Butterworth-Heinemann

  4. Livitsanos C, Thomson P (1977) The effect of temperature and deformation rate on transformation-dependent ductility of a metastable austenitic stainless steel. Mater Sci Eng 30:93–98

    Article  CAS  Google Scholar 

  5. Takuda H, Mori K, Yamazaki E, Watanabe Y (2003) Finite element analysis of the formability of an austenitic stainless steel sheet in warm deep drawing. J Mater Process Technol 143:242–248

    Article  Google Scholar 

  6. Gardner L (2005) The use of stainless steel in structures. Prog Struct Eng Mater 7:45–55

    Article  Google Scholar 

  7. Billur E, Mahabunphachai S, Koç M (2009) Formability of austenitic stainless steels under warm hydroforming conditions. Transactions of NAMRI/SME 37:341–348

    Google Scholar 

  8. Saada FB, Elleuch K (2017) Tribological behavior of 304 L stainless steel used for olive oil extraction. Mechanics & Industry 18:207

    Article  Google Scholar 

  9. Man J, Kuběna I, Smaga M, Man O, Järvenpää A, Weidner A, Chlup Z, Polák J (2016) Microstructural changes during deformation of AISI 300 grade austenitic stainless steels: impact of chemical heterogeneity. Procedia Structural Integrity 2:2299–2306

    Article  Google Scholar 

  10. Naka T, Yoshida F (1999) Deep drawability of type 5083 aluminium–magnesium alloy sheet under various conditions of temperature and forming speed. J Mater Process Technol 89:19–23

    Article  Google Scholar 

  11. Kurukuri S, Boogaard vdA, Ghosh M, Miroux A (2010) Thermo-mechanical forming of Al–Mg–Si alloys: modeling and experiments. AIP Conference Proceedings AIP pp. 810–817

  12. Ghaffari Tari D, Worswick M, Winkler S (2013) Experimental studies of deep drawing of AZ31B magnesium alloy sheet under various thermal conditions. J Mater Process Technol 213:1337–1347

    Article  CAS  Google Scholar 

  13. Ghosh M, Miroux A, Werkhoven R, Bolt P, Kestens L (2014) Warm deep-drawing and post drawing analysis of two Al–Mg–Si alloys. J Mater Process Technol 214:756–766

    Article  CAS  Google Scholar 

  14. Panicker SS, Panda SK (2017) Improvement in material flow during nonisothermal warm deep drawing of nonheat treatable aluminum alloy sheets. J Manuf Sci Eng 139:031013

    Article  Google Scholar 

  15. Shinagawa K, Mori K-i, Osakada K (1991) Finite element simulation of deep drawing of stainless steel sheet with deformation-induced transformation. J Mater Process Technol 27:301–310

    Article  Google Scholar 

  16. Singh SK, Mahesh K, Kumar A, Swathi M (2010) Understanding formability of extra-deep drawing steel at elevated temperature using finite element simulation. Mater Des 31:4478–4484

    Article  CAS  Google Scholar 

  17. Ethiraj N, Kumar VS (2012) Finite element method based simulation on warm deep drawing of AISI 304 steel circular cups. Procedia Eng 38:1836–1851

    Article  CAS  Google Scholar 

  18. Jayahari L, Naik BB, Singh SK (2014) Effect of process parameters and metallographic studies of ASS-304 stainless steel at various temperatures under warm deep drawing. Procedia Mater Sci 6:115–122

    Article  CAS  Google Scholar 

  19. Goud RR, Prasad KE, Singh SK (2014) Formability limit diagrams of extra-deep-drawing steel at elevated temperatures. Procedia Mater Sci 6:123–128

    Article  CAS  Google Scholar 

  20. Jayahari L, Balunaik B, Gupta AK, Singh SK (2015) Finite element simulation studies of AISI 304 for deep drawing at various temperatures. Materials Today: Proceedings 2:1978–1986

    Article  Google Scholar 

  21. Myers RH, Montgomery DC, Anderson-Cook CM (2016) Response surface methodology: process and product optimization using designed experiments. John Wiley & Sons

  22. Montgomery DC (2017) Design and analysis of experiments, John Wiley & Sons

  23. Owen M, Cox I (2018) Design of experiments. Pharmaceutical quality by design: A practical approach 157

    Chapter  Google Scholar 

  24. Barad M (2018) Design of experiments (DOE), strategies and techniques for quality and flexibility. Springer pp. 61–79

  25. Chen J, Young B (2006) Stress-strain curves for stainless steel at elevated temperatures. Eng Struct 28:229–239

    Article  Google Scholar 

  26. Kumar MV, Balasubramanian V, Rao AG (2017) Hot tensile properties and strain hardening behaviour of super 304HCu stainless steel. J Mater Res Technol 6(2):116–122

    Article  Google Scholar 

  27. Desu RK, Krishnamurthy HN, Balu A, Gupta AK (2016) Mechanical properties of austenitic stainless steel 304L and 316L at elevated temperatures. J Mater Res Technol 5(1):13–20

    Article  CAS  Google Scholar 

  28. Browne M, Hillery M (2003) Optimising the variables when deep-drawing CR 1 cups. J Mater Process Technol 136:64–71

    Article  Google Scholar 

  29. Brable G, Nanu N, Radu EM (2008) Deep drawing tools and process optimization based on Taguchi and LMecA-Taguchi methods for the compensation of errors generated by springback, Proceedings of National Conference on Excellence Research− A way to Innovation, Brasov. pp. 27–29

  30. Jayahari L, Sasidhar P, Reddy PP, BaluNaik B, Gupta A, Singh SK (2014) Formability studies of ASS 304 and evaluation of friction for Al in deep drawing setup at elevated temperatures using LS-DYNA. J King Saud Univ Eng Sci 26:21–31

    Article  Google Scholar 

  31. Lange K (1985) Handbook of metal forming. McGraw-Hill Book Company, Stuttgart

    Google Scholar 

  32. Reddy RV, Mounika V, Raju PR (2018) Effect of various process parameters on punch and die design in deep drawing process. IJITR 5:7684–7691

    Google Scholar 

  33. Joglekar A, May A (1987) Product excellence through design of experiments. Cereal Foods World 32:857–868

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University of Zanjan, Zanjan, 45371-38791, Iran

    S. Alinia, R. Khamedi & I. Ahmadi

Authors
  1. S. Alinia
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. R. Khamedi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. I. Ahmadi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to R. Khamedi.

Ethics declarations

Conflict of Interest

The authors declare that they have no conflict of interest.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Alinia, S., Khamedi, R. & Ahmadi, I. The Investigation and Optimization of Process Parameters in Warm Deep Drawing of ASS304 Steel Using Box Behnken Design and Applying Temperature Gradient. Exp Tech 42, 645–657 (2018). https://doi.org/10.1007/s40799-018-0285-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40799-018-0285-7

Keywords

Search

Navigation