Enhancing formability in hydromechanical deep drawing process adding a shallow drawbead to the blank holder |
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| Affiliation: | 1. Department of Mechanical Engineering, Faculty of Engineering, Selcuk University, Konya, Turkey;2. Department of Mechanical Engineering, Faculty of Engineering and Architecture, Necmettin Erbakan University, Konya, Turkey;1. Laboratory for Numerical Modelling and Simulation, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia;2. Cimos d.d., Automotive Industry, Koper, Slovenia;1. Glyndŵr University, Department of Engineering and Applied Physics, Mold Road, Wrexham LL11 2AW, UK;2. Aalen University of Applied Sciences, Institute of Surface and Materials Sciences, Beethovenstr. 1, Aalen 73430, Germany;3. Aalen University of Applied Sciences, Centre of Optical Technology, Anton-Huber-Str. 21, Aalen 73430, Germany;1. Mechanical and Mechatronics Engineering, University of Waterloo, 200 University Ave. W., Waterloo, Ontario N2L 3G1, Canada;2. Dana Power Technologies, 656 Kerr St., Oakville, Ontario L6K 3E4, Canada;1. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, PR China;2. Research and development center of Wuhan iron and steel (group) corp, Wuhan 430074, PR China |
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| Abstract: | In this paper, a new method was proposed in order to enhance the limiting drawing ratio (LDR) of AA5754-O in the hydromechanical deep drawing process (HDD). In the proposed method, a shallow drawbead was added to the blank holder to increase LDR so as to provide strain hardening of a large region on the flange of the sheet material in addition to pre-bulging process which affects particularly only the initial stage but not the later ongoing process. So the LDR of the AA5754-O was increased from 2.65 to 2.787 by enlarging the region of strain hardening in the flange and partially reducing wrinkling tendency due to occurred tensile stresses using the convenient pressure and blank holder force profiles. The importance levels and their convenient values for height of drawbead, pre-bulge height and pressure, surface roughness of the punch were determined with analysis of variance (ANOVA) is a statistical method. ANOVA analysis illustrated that adding a shallow drawbead to the blank holder is the most effective factor between the investigated factors for the HDD process. While the effects of the pre-bulging pressure and pre-bulging height were determined as quite small, the surface roughness of the punch was found unimportant compared to the effect of the shallow drawbead. The highest LDR value was obtained with 1 mm drawbead height, 5 mm pre-bulging height, 10 MPa pre-bulging pressure and 2.8 μm surface roughness of the punch. |
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| Keywords: | Hydromechanical deep drawing Limiting drawing ratio Strain hardening ANOVA AA5754-O |
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