Document Type : Research Paper
Authors
Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
Abstract
The manufacturing industry heavily relies on deep drawing due to its remarkable ability to produce intricate symmetrical and asymmetrical shapes with accuracy and efficiency. This research aimed to create a deep drawing tool capable of producing a pentagonal cup measuring 41mm in diameter and 30mm in height. This was achieved by conducting numerical simulations and experimental tests using two different methods. The first method involved converting an 80mm diameter circular blank into a pentagonal cup through a drawing operation, while the second method involved redrawing a cylindrical cup into a pentagonal shape. The study also analyzed the impact of these methods on the drawing load, stress/strain distributions, and thickness distributions. The finite element method software, ANSYS 20, was employed for numerical simulations. The results showed that the first method had a significantly higher punch load than the second method. However, the pentagonal cup produced using the first method had a greater thickness reduction towards the cup wall curvature compared to those produced using the second method. Therefore, the second method was considered ideal for manufacturing a pentagonal cup because it resulted in a lower degree of thinning at the cup curvature and a more uniform distribution of thickness, stress, and strain. In conclusion, this research highlights the importance of deep drawing in the manufacturing industry and emphasizes the need to choose the appropriate forming method to achieve optimal results.
Graphical Abstract
 "Experimental and Theoretical Analysis to Produce Pentagonal Cup in Deep Drawing Process")
Highlights
- Fabricate pentagonal cups using two different methods: the direct technique and the conversion technique.
- The second forming method is the best method to produce a pentagonal cup.
- Complex shapes in the deep drawing process can be produced using the second forming method.
Keywords
Main Subjects
- P. Pradipkumar , K.H. Inamdar, A Review on Deep Drawing of Rectangular Shaped Parts, Asian J. Convergence Technol., 2 ( 2016)1-3.
- S. Kang , W. J . Song , T. W. Ku, Study on process parameters and its analytic application for non-axisymmetric rectangular cup of multistage deep drawing process using low carbon thin steel sheet, Int. J. Adv. Manuf. Technol., 49 (2010) 925–940. https://doi.org/10.1007/s00170-009-2450-8
- I. Mohammed, Analysis of Forming Complex Cup by Drawing Process , IOP Conf. Ser.: Mater. Sci. Eng., 881 , 2020, 012055. https://doi.org/10.1088/1757-899X/881/1/012055
- K. Kushwaha. , V. Babele , D. N .Verma , Experimental investigation of sheet metal forming without blank holder using punch stamping process , Int. J. Res. Emerging Sci. Technol., 4 (2017) 1-38.
- A .H . Saleh,.H. A. Ameen , O. Abed Al Radh , Deep drawing of sheet metals using the friction-actuated blank-holding technique , Int. J. Eng.Technol., 7 (2018) 578-583. https://doi.org/10.1088/1757-899X/881/1/012055
- K .Jawad , A. T . Ikal, Effect of radial clearance on stress and strain distribution in the astral deep drawing , J. Eng. Technol., 37 (2019). https://doi.org/10.30684/etj.37.8A.4
- T .S .Atul , L .Babu , M. Chinnapandi , Multi-stage deep drawing process of axis-symmetric extra deep drawing steel cylindrical cup, Eng. Res. Express, 2 (2020) 025008. https://doi.org/10.1088/2631-8695/ab872a
- M. AL-Darraj, A. S. Jaber, Experimental and theoretical study of square deep drawing, J. Eng. Technol., 29 (2011) 2456-2467.
- Gowtham, K. Srikanth, K. Murty, Simulation of the effect of die radius on deep drawing process, Int. App. Res. Mech. Eng., 1 ( 2012) 12-17. https://doi.org/10.47893/IJARME.2012.1043
- Dou, J.Xia , Numerical analysis of sheet metal drawing and redrawing process, J. Eng. Des., 17 (2015) 625-630.
- H.O baeed , Numerical and experimental explorations for the formability of drawing square cups through deep drawing operation, Eng. Technol. J., 38 (2020) 1316-1326. https://doi.org/10.30684/etj.v38i9A.1340
- J .Jweeg, A. I. Mohammed, and M. S .Jabbar, Investigation of Thickness Distribution Variation in Deep Drawing of Conical Steel Products , Eng. Technol. J., 39 (2021) 586-598. https://doi.org/10.30684/etj.v39i4A.1908
- S. Choudhari, S.S. Khasbage, Experimental investigation of forming parameters for square cup deep drawing process, Mater. Today: Proc., 44 (2021) 4261-4267. https://doi.org/10.1016/j.matpr.2020.10.543
- Barkanov, E. Intriduction to the Finite Element Method, Institute of Materials and Structures, Faculty of Civil Engineering, Riga Technical University, 2001.
- N. Reddy, An Introduction to the Finite Element Method, McGraw-Hill series in mechanical engineering, 1993.
- Ghosh, A.K. Mallik, Manufacturing Science, Affiliated Ease-West Press Publishers Ltd., India,1985.
- Kajikawa, T. Takasan, T. Kuboki , K. Tamaoki, K. onishi, A. Gunji, And A. Yamauchi, Finite element analysis of multi-stage deep drawing for forming deep rectangular case with high aspect ratio, Presentations and videos to 16th Int. Conf. Comput. Plast., IS02, 2022. https://doi.org/10.23967/complas.2021.032
- H .Mukhirmesh , W. K. Jawad , The procedure of experimental work and finite element simulation to produce spline shape multi-stage deep- drawing operation , Conf. Ser. Mater. Sci. Eng., 2021, 1094-012133. https://doi.org/10.1088/1757-899X/1094/1/012133
- S. Choudhari, S.S. Khasbage, Experimental investigation of forming parameters for square cup deep drawing process, Mater. Today. Proc., 44 (2021) 4261-4267. https://doi.org/10.1016/j.matpr.2020.10.543
)
