Abstract
Still today, the analysis and design of deep drawing is an art rather than science. In this paper, an attempt was made to study the deep drawing process for experimental determination of Limiting Drawing Ratio (LDR) and justify the results with simulations. The use of FE simulation software can predict sheet metal forming process such as deep drawing and also enhances the efficiency by reducing development time and cost. The deep drawing experimental tests were carried out, using the tool setup ingeniously developed in the lab and mounted on universal testing machine. The AA6111 aluminum alloy sheet blanks of different sizes were drawn using optimum forming conditions established through Taguchi design of experiments. The drawn cups were tested for wrinkling and cracks, if any and determined the LDR by considering the maximum size of the blank successfully drawn without these defects. The LDR found in this study for AA6111 was 1.8325. The simulation tests were conducted using the FE code Pam-Stamp and are in good agreement with the experimentally drawn cups when inspected for wrinkles and cracks. The forming limit diagram in each test shows that the strains were within safe limit for the successfully drawn cups and exceeded the limit in case of fractured and/or wrinkled cups.
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References
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Sekhara Reddy, A.C., Rajesham, S., Mahender, T. (2020). Experimental and Simulation Study in Deep Drawing of Circular Cups for Determination of LDR. In: Satapathy, S., Raju, K., Molugaram, K., Krishnaiah, A., Tsihrintzis, G. (eds) International Conference on Emerging Trends in Engineering (ICETE). Learning and Analytics in Intelligent Systems, vol 2. Springer, Cham. https://doi.org/10.1007/978-3-030-24314-2_64
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DOI: https://doi.org/10.1007/978-3-030-24314-2_64
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