Journal of Failure Analysis and Prevention

, Volume 16, Issue 3, pp 361–368 | Cite as

Deep Drawing Failure Map of a Coated Metal Sheet Based on the Process Parameters

Technical Article---Peer-Reviewed

Abstract

Fracture and wrinkling are two main failure modes in deep drawing of a coated metal sheet. With the development of damage mechanics and finite element modeling, it is possible to exactly predict the failure mode of a material during deep drawing. In this paper, a coated metal sheet during deep drawing is studied by finite element simulation and dimensional analysis. Based on a few dimensionless process parameters, a failure map is established, which can be divided into three regions including fracture, wrinkling, and success.

Keywords

Failure map Deep drawing Coated metal sheet Finite element simulation Dimensional analysis 

Notes

Acknowledgment

This work was supported by the following Natural Science Funding of Hunan Province (Nos. 2015JJ6029; 15B059; 2015KG65), Startup Foundation for Doctor Degree of HNIT (No. HQ13010).

References

  1. 1.
    A.G. Mamalis, D.E. Manolakos, A.K. Baldoukas, On the finite element modeling of the deep-drawing of square sections of coated steels. J. Mater. Process. Technol. 53, 153–159 (1996)CrossRefGoogle Scholar
  2. 2.
    M.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems (Wiley, Hoboken, 2001)Google Scholar
  3. 3.
    Z.Q. Sheng, S. Jirathearanat, T. Altan, Adaptive FEM simulation for prediction of variable blank holder force in conical cup drawing. Int. J. Mach. Tools Manuf 44, 487–494 (2004)CrossRefGoogle Scholar
  4. 4.
    M.M. Moshksar, A. Zamanian, Optimization of the tool geometry in the deep drawing of aluminium. J. Mater. Process. Technol. 72, 363–370 (1997)CrossRefGoogle Scholar
  5. 5.
    H. Naceur, Y.Q. Guo, J.L. Batoz, C. Knopf-Lenoir, Optimization of drawbead restraining forces and drawbead design in sheet metal forming process. Int. J. Mech. Sci. 43, 2407–2434 (2001)CrossRefGoogle Scholar
  6. 6.
    J. Cao, M.C. Boyce, A predictive tool for delaying wrinkling and tearing failures in sheet metal forming. J. Eng. Mater. Tech. 119, 354–365 (1997)CrossRefGoogle Scholar
  7. 7.
    L.F. Menezes, C. Teodosiub, Three-dimensional numerical simulation of the deep-drawing process using solid finite elements. J. Mater. Process. Technol. 97, 100–106 (2000)CrossRefGoogle Scholar
  8. 8.
    Q.F. Chang, D.Y. Li, Y.H. Peng, X.Q. Zeng, Experimental and numerical study of warm deep drawing of AZ31 magnesium alloy sheet. Int. J. Mach. Tools Manuf. 47, 436–443 (2007)CrossRefGoogle Scholar
  9. 9.
    Y.Q. Guo, Y.M. Li, F. Bogard, K. Debray, An effcient pseudo-inverse approach for damage modeling in the sheet forming process. J. Mater. Process. Technol. 151, 88–97 (2004)CrossRefGoogle Scholar
  10. 10.
    H. Badreddine, K. Saanouni, A. Dogui, On non-associative anisotropic finite plasticity fully coupled with isotropic ductile damage for metal forming. Int. J. Plast. 26, 1541–1575 (2010)CrossRefGoogle Scholar
  11. 11.
    C.C. Tasan, J.P.M. Hoefnagels, C.H.L.J. ten Horn, M.G.D. Geers, Experimental analysis of strain path dependent ductile damage mechanics and forming limits. Mech. Mater. 41, 1264–1276 (2009)CrossRefGoogle Scholar
  12. 12.
    J.B. Kim, J.W. Yoon, D.Y. Yang, F. Barlat, Investigation into wrinkling behavior in the elliptical cup deep drawing process by finite element analysis using bifurcation theory. J. Mater. Process. Technol. 111, 170–174 (2001)CrossRefGoogle Scholar
  13. 13.
    P. Nordlund, B. Haggblad, Prediction of wrinkle tendencies in explicit sheet metal-forming simulations. Int. J. Numer. Methods Eng. 40, 4079–4095 (1997)CrossRefGoogle Scholar
  14. 14.
    S. Yossifon, K. Sweeney, M. Ahmetoglu, T. Altan, On the acceptable blank-holder force range in the deep-drawing process. J. Mater. Process. Technol. 33, 175–194 (1992)CrossRefGoogle Scholar
  15. 15.
    M. Ahmetoglu, T.R. Broek, G. Kinzel, T. Altan, Control of blank holder force to eliminate wrinkling and fracture in deep-drawing rectangular parts. CIRP Ann. Manuf. Technol. 44, 247–250 (1995)CrossRefGoogle Scholar
  16. 16.
    Y.G. Liao, Y.C. Zhou, Y.L. Huang, L.M. Jiang, Measuring elastic–plastic properties of thin films on elastic–plastic substrates by sharp indentation. Mech. Mater. 41, 308–318 (2009)CrossRefGoogle Scholar
  17. 17.
    L.Q. Zhou, Y.P. Li, Y.C. Zhou, Numerical analysis of electrodeposited nickel coating in multisting drawing processes. J. Eng. Mater. Tech. 127, 233–243 (2005)CrossRefGoogle Scholar
  18. 18.
    H. Gharib, A.S. Wifi, M. Younan, A. Nassef, Optimization of the blank holder force in cup drawing. J. Achiev. Mater. Manuf. Eng. 18, 291–294 (2006)Google Scholar
  19. 19.
    L. Gunnarsson, N. Asnafi, E. Schedin, In-process control of blank holder force in axi-symmetric deep drawing with degressive gas springs. J. Mater. Process. Technol. 73, 89–96 (1998)CrossRefGoogle Scholar
  20. 20.
    M.R. Morovvati, B. Mollaei-Dariani, M.H. Asadian-Ardakani, A theoretical, numerical, and experimental investigation of plastic wrinkling of circular two-layer sheet metal in the deep drawing. J. Mater. Process. Technol. 210, 1738–1747 (2010)CrossRefGoogle Scholar
  21. 21.
    T.X. Yu, W. Johnson, The buckling of annular plates in relation to the deep-drawing process. Int. J. Mech. Sci. 24, 175–188 (1982)CrossRefGoogle Scholar
  22. 22.
    H. Hooputra, H. Gese, H. Dell, H. Werner, A comprehensive failure model for crashworthiness simulation of aluminium extrusions. Int. J. Crashworthy. 9, 449–464 (2004)CrossRefGoogle Scholar
  23. 23.
    R.K. Saxena, P.M. Dixit, Prediction of flange wrinkling in deep drawing process using bifurcation criterion. J. Manuf. Proc. 12, 19–29 (2010)CrossRefGoogle Scholar

Copyright information

© ASM International 2016

Authors and Affiliations

  1. 1.Engineering Training CenterHunan Institute of TechnologyHengyangChina

Personalised recommendations