Study of The Stress and Strain Distribution During Deep Drawing and Ironing Process of Metals with A Circular Profiled Die.

Abstract

In this study a numerical procedure was proposed for the design of deep drawing process using finite element method (F.E.M) through program code (ANSYS 5.4) simplified 2-D ax symmetric model of cylindrical cup are been developed. This work aims to study the effect of some parameters which influence the drawing process such as: Die geometries, friction coefficient, slight tilt and to predict the tearing failure in drawn part.  The combined deep drawing and ironing process analyzed in the manufacturing of thin-walled cans; the subsequent stages are pure ironing stages. In the production it was found that it is extremely important that the cup produced in the deep drawing and ironing stage has an even height. The die used was made with a cylindrical die land and detailed FEM-simulations show that an uneven cup height can be caused by a slight tilt of the die and or punch. The result showed that, the increasing the value of friction coefficient from (0.1) leading to increasing the cup height about (3) mm and this leading to predict the tearing failure in drawn part, so Instead of using a die with a cylindrical die land it is suggested to make the die land with a circular profile. FEM-simulations show that if the die made with a circular profiled die land the cup produced is nearly unaffected by a slight tilt of the punch and or die. The FEM-simulations thus strongly indicate that the combined deep drawing and ironing process becomes significantly more robust when the die is made with a circular profiled die land compared with experiment result and when a conventional die design with a cylindrical die land is used.