A numerical study on warm deep drawing of polypropylene

Warm deep drawing of polypropylene, a semi-crystalline thermoplastic polymer, is studied using finite element analysis. In this process, a circular polypropylene blank is preheated to a temperature much below its melting temperature and deep drawn into the shape of a flat-bottom cylindrical cup using a punch-die combination, both initially at 25°C. The material model used for the analysis considers the effects of varying temperature and strain rate during the deep drawing process on the depth of draw. The effects of blank holder force, initial blank temperature, blank diameter, and die and punch corner radii on the depth of draw are determined. Thickness, temperature, and strain variations in the drawn cups, punch forces, and failure modes are also determined.