)(Deep Drawing

 :


...

.

) (
.

.


.

.


: 4................................................................................................
1-1 4 ..................................................................................................................................
2-1 4 ......................................................................................................................
.3-1

: 7 ................................................
.1-2 7 .......................................................................................................
2-2 .......................................................................

10

3-2 .. ...........................................................................................

11

4-2 .................................................................................................

11

5 -2 .............................................................................

12

6-2 .............................................................................................................

13

7-2 ..........................................................................................................

14

8-2 ...................................................................................................

15

9-2 .................................................................................................

16

: 18 ..................................................
1-3 ...................................................................................................................................

18

2-3 20 ........................................................
3-3 24 ...........................................

: 31 ..........................
1-4 31..........................................................................................................................................
2-4 33 .....................................
3-4 33............................................................................
.1-3-4 35 ................................
2-3-4 ...................................

36

3-3-4 ) ( 37 ...............................................
4-4 38 .............................................................
1-4-4 ..................................................................................................................

38

.2-4-4 ....................................................................

39

 : 40 ...........................................................

: . 54 ................................................

60 ................................................................................................... :



. 1-1 :
-

.


.
.

) 1 ( ][

-2-1 :
.
2 .

 2 ) (

- 2 ) ( ][

.
[1] :

 )(Pure Drawing - )(Ironing

.3-1 ][2
:
( - ) ( ) ( .
( .
( ) ( .
.
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catia
solid works ) ( Surface of Element Area
.
[3] .

][3

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.
3 ) ( [3] .

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.
:
.
= 2 2
. 1,3
1,7 [3] .

blank
part

final

= tot

tot = 1 2 .......

10

 :
ozul [2] :

D
d

= ozul

D d .

d
2
s

1 d .

ozul USt 1303 Mn 63 Al 99.5 WUSt 1403 .

600

500

450

400

350

300

250

200

150

100

50

30

1,5

1,60

1,65

1,7

1,75

1,8

1,85

1,9

1,95

2,0

2,05

2,1

ozul

][2

. 3-2 ][4
. :

d i 1 d i
100
d i 1
:
di

= Re

= d i 1
.4-2
[2] :

:
= hi
. 1 s .

11

D 2 di
= hi
2
4d i

 = d i
= D
. 5-2
) ( .
:
: [2] :
D
d

w=s

:
= W ) ( mm
= D ) ( mm
= d ) ( mm
= S ) ( mm
: [2] :
.
w= s+k s

= k .

0,04

0,02

0,2

0,07

12

mm

 : : ][2
:

for steel
for Al

w = e + 0.07 10e
w = e + 0.02 10e

w = e + 0.04 10e

for others
:
= e )( mm

.6-2
:
) ( 3-2-1 .
) ( .

:
4 5
[2] .
" " sheet metal forming and die design
[1] :

for first stage

for other stages

) rp = 0.8 ( D d1
) rp = 0.8 (d1 d i

" " Die Design HandBook

[4] :

13

a
30

t stock
0.32-0.8 mm

40

0.8-1.6 mm

45

over 1.6 mm

.7-2
:
][2
Dm = D p + 2 w

:
= Dm
= D p
= w

:
.
[2] :

0.035
[50mm + (D d )] s
mm
:

= rm

= rm ) ( mm
= D ) ( mm
= d ) ( mm
= S ) ( mm

14

 [4] :

rm1 = 0.8(D d ) t

d i 1 d i
t
2

= rmi

:
= rm ) ( mm
= D ) ( mm
= d ) ( mm
= t ) ( mm
.8-2


:
: [2] :
:

F1 = u s Rm n
:

F1
+ d1 s Rm n
2
:
= Fi

= Fi

) (KN

= d1 )(mm
= s )(mm
= Rm )(MPa
= n

15

= )(mm

: ][5

D
] 0.7
di
:

[ ) Fi = d i t (uts

= Fi

) (KN

= d i )(mm
= t )(mm
= uts )(MPa
= D )(mm

.9-2


:
: ][2
:
di
R
pi = [( Btat 1) 2 +
] m
200 s 400
FBH i = Ai pi pi Ai
. :

) Ai = ( D 2 dwi

dwi = d i + 2 w + 2 rm
:

) (MPa

= pi
= di )(mm
= w )(mm
= Rm )(MPa

16

 = Ai )(mm

= FBHi

) (KN

= rm ) ( mm
= D )(mm
= s )(mm
= Btat

: ][3

:
[ D 2 (d m + 2rm ) 2 ] P

:
= FBi

= FBi

) (KN

= d m )(mm
= rm )(mm
= D )(mm
= P Al 1,2 1,5 .

17

 :
. 1-3 :

.
.
:
] [5

)(

Sheet Metal Forming and Die Design [3] :

4
5

. Unsatiesfies
. Material and Friction Factors
4
. Strain Hardening coefficient
5
. Normal Anisotropy
3

18

:


.

)(


.

) (.

5 6
.

. Tooling and Equipment Factors

19

 5 ][11

][12

.
. 2-3 ][3
:

.1 :
:

20

.2 :
:
.1
.2
.3
.4
.5

.
.
.
.
.

7 .

[13] 7

:
.1
.2
.3
.4
.5
.6
.7

21

 .3 : ) . ( 8
:

: )(

[14] 8

.4 : .
:
:
.1 ) ( ) (
.2

.3

.5 : 9 .
) ( 9
:
7

. Change the blank shape

. Recess Material in the Affected Areas
9
. Vessel Wall
8

22

[15] 9

:
.1
.2
.6 : ) . ( 10
:
.
:

[16] 10

23

 .7 : ) ( ) ( 11
:

)( .

[17] 11

:
.1 )(
.2
.3
. 3-3 ][5

:
.1 ) : ( 12

. 1 ( : % 40
.
:

:

24

12

][13

. 1 ( : .
:
.
:

. 1 ( : .
:
.
:

25

 . 1 ( :
:

)( .

:
.1
.2
.3

. 1 ( :
.
:
.
:
.

.2 : ) . (

13

26

][5

 : :
-
-
-
-
:

.3 : ) . ( 14

14

)( .

:
.1
.2
.3

27

][18

 .4 : 10 ) . (
) ( 15
:
11 .
:

15

][17

.5 : ) . ( 16

16

:
)( .
:
.
. Earing
. Planner Anisotropy

28

10
11

 .6 : ) . ( 17
:

17

][5

: :
-
- )(
12
-
-

.7 : ) : ( 18
- )(a
- )(b
- (c) .

18

][5

:
)(
) . ( .

. Draw Bead

29

12

 :
.1
.2
.3
.4
.5

)(



- )(

:
.
)( .
.8 :
Slip Bands .
.
) . ( 19

19

][5

:
13

Slip -
.
:
.

. Age - Sensitive

30

13

 :
. 1-4
.

.

ABAQUS LS-DYANA ANSYS

.
:
: : [19] :
-1
-2
-3
-4

.
.
) ( .
.

: : :
-1
-2
-3
-4

.
.
.

.

31


[19] :

.
[19] .

.
.
. ) (
.
.

.
.
.
.
[19] .
:
-1
-2
-3 : .

:

32

 . 2-4 ][6
:
)(
)(
.

.
: .
.
.

:

. 14

. 15

.3-4 :

:
( ). ( 20-a
( ) . ( 20-b

20

. Elastic Recovery
. compression instability

33

14
15


.
.

.
21 :

21

Rd = 40mm, rd = 7.5mm, R p = 38.2mm, rp = 8mm

21 .

22

150mm 1mm
) ( DC05 .
; Young modulus E = 191 GPa
; Poissons ratio = 0,34
; Flow stress = 187 MPa
; Strain hardness coefficient n = 0,189
Maximum limit strength = 299 MPa

34

 . 1-3-4 :
21 .
mm
18
.
min
10mm 40mm . 5 1 :

40

35

30

25

20

15

10

mm

5,5

2,3

1,4

0,9

0,6

Fr = 20 KN

3,2

2,8

2,1

1,8

1,2

0,8

0,5

Fr = 80 KN

0,65

0,6

0,45

Fr = 150 KN

0,6

0,5

0,2

Fr = 200 KN

. . 1
. .
150KN 200KN
.
. 1
.

35

 . 2-3-4 :
) (2 30mm

.
.
30

40

35

3,2

2,8

2,1

2,8

2,5

1,9

mm

25

20

15

10

2,1

1,4

0,9

0,5

2,3

1,4

0,9

0,5

rp = 5mm

1,8

1,2

0,8

0,5

rp = 8mm

1,6

1,2

0,8

0,5

rp = 10mm

rp = 2mm

* Fr = 80 KN
rp *
6

.
.

36

 . 3-3-4 ) ( :
:
= 0.01 , 0.05 , 0.1 rp = 8mm Fr = 80 KN
.
7 3 :

40

35

30

25

20

15

10

mm

3,3

2,8

2,5

1,5

0,9

0,5

3,2

2,8

2,1

1,8

1,2

0,8

0,5

0,4

0,3

0,2

= 0.01
= 0.05
= 0.1

.
.

37

 :

.
.
.

.
.4-4 ][7
. 1-4-4 :

.

.
:
16
.
.
17 ) . (4

. Normal Stress
. Process Window

38

16
17

 .
.
. 2-4-4 :
23 :
FP = 2r1t1 ( r)1 sin
:

Fp
r1 1
t1 1
r 1

23

FBH = V0 + V1 L
:

FBH
V0
V1
L
:
Fwrinkling FBH Ftearing

39

 :
.
. :

Al 7075

2.5 mm

175 mm

181 mm

12 mm
8

24

[2] .

]) D = (d 2r ) 2 + 4 1.57r (d 2r ) + 2r 2 + d (h r
d .

25

= 397.81 400 mm

)D = (183.5 24) 2 + 4[1.57 (12) (183.5 24) + 2(12) 2 + 183.5(175 12

40

 .

:

26

)(mm

)(mm

)(mm

R1
)(mm

2.6

15

265,2

25

12

2.6

25

213,6

20

12

%20

2,6

16

186,2

12

12

%13

H
)(mm

d
)(mm

R2
)(mm

88

260

%35

208

140

181

175

41

) -27 (

)- 28 (

) -29 ( ) (

:1 [5] kurt lange

D
] 0.7
di

[ ) Fi = d i t (uts

42

 :
= Fi

) (KN

= d i )(mm
= t )(mm
= uts )(MPa
= D )(mm

400
0.7] = 376.5 KN
260

[ )F1 = 260 2.5 ( 220

44.8 tonf

400
0.7] = 439.35 KN
208

[ )F2 = 208 2.5 (220

48.13 tonf

400
0.7] = 471.99 KN
181

[ )F3 = 181 2.5 (220

38.4 tonf

Drawing Force - Kurt Lange

60

50

48.13
44.8
38.4

40

20

10

0
3rd Stage

2nd Stage

43

1st Stage

Tonf

30

 : 2 [3] schuler
B 1
Bmax 1
= Fi

Fi = (d1 + s ) s Rm 1.2

) (KN

= d1 )(mm
= Rm )(Mpa

=
= max
Bmax = 2

29.4 tonf

= 288.32 KN

1.53 1
2 1

= 194.3 KN

1.25 1
1.7 1

= 253.86 KN

1.14 1
1.3 1

F1 = (260 + 2.5) 2.5 220 1.2

if annealed Bmax = 1.7

19.81 tonf

F2 = (260 + 2.5) 2.5 220 1.2

Bmax = 1.3

25.8 tonf

44

F3 = (260 + 2.5) 2.5 220 1.2

Drawing Force - Schuler

35

29.4
25.8

30

25

20

19.81

Tonf
15

10

0
3rd Stage

2nd Stage

1st Stage

: 3 ][2

F1 = u s Rm n
F1
+ d1 s Rm n
2
:

= Fi

= Fi

) (KN

= d1 )(mm
= s )(mm
= Rm )(MPa
= n
= U )(mm

400
= 1.53 n = 0.6
260

45

= Btat

F1 = (816.4) 2.5 220 0.6 = 269.4 KN

27.5 tonf

Btat = 1.25 n = 0.35

F2 = (134 .7) + 260 (3.14) 2.5 ( 220) 0.35 = 291.85

KN

29.8 tonf

Btat =
F3 = (134.7) + 260 (3.14) 2.5 ( 220) 0.25 = 247 KN

208
= 1.14 n = 0.25
181

25.2 tonf

Drawing Force - forming practical engineering

31
30

29.8

29
28

Tonf

27.5
27
26
25.2

25
24
23
22
1st Stage

2nd Stage

10

46

3rd Stage

 :4 ][4
D
] c
di
= Pi ) (KN
= di )(mm
= t )(mm
[ Pi = d i ts y

= S y )(MPa
= D )(mm
= C 0,6 0,7

* s y AL7075 95MPa .

= 16.6Tonf

400
0.7] = 162.6KN
260

[)P1 = (260)(2.5)(95

= 19.35Tonf

400
0.7] = 189.7KN
208

[)P2 = (208)(2.5)(95

= 20.8Tonf

400
0.7] = 203.8KN
181

[)P3 = (181)(2.5)(95

Drawing Force - Suchy

25

20.8

20

19.35
16.6

15
Tonf
10

0
3rd Stage

2nd Stage

11

47

1st Stage

 : 5 ) (

)(Tonf

18,3

22,8

22,8
10

Drawing Force - Exprimental

25
22.8

22.8
20
18.3

15

Tonf
10

0
3rd Stage

2nd Stage

12

48

1st Stage

:1 ][3
[ D 2 (d m + 2rm ) 2 ] P

= FB

:
= Fi

) (KN

= d m )(mm
= rm )(mm
= D )(mm
= P Al 1,2 1,5 .

= 85.8 KN

[4002 (265.2 + 30) 2 ] 1.5

8.75 tonf

10.87 tonf

= 106.6 KN

[400 2 (213.6 + 50) 2 ] 1.5

13.5 tonf

= 132.34 KN

[4002 (186.2 + 32) 2 ] 1.5

49

= FB1

= FB2

= FB3

Blank Holder Force - Schuler

16

14

13.5

12
10.87
10

Tonf

8.75
8
6
4

2
0
3rd Stage

2nd Stage

1st Stage

13

:2 ][2
di
R
] m
200 s 400

pi = [( Btat 1) 2 +

) Ai = ( D 2 dwi

dwi = d i + 2 w + 2 rm

FBH i = Ai pi
:

) (MPa

= pi
= di )(mm
= w )(mm
= Rm )(MPa
= Ai )(mm

50

(KN )

= FBH i

( mm ) = rm
(mm) = D
= Btat
(mm) = s

dw1 = 260 + 2(2.6) + 2(15) = 295.2 mm

A1 = (400 2 (295.2) 2 )
p1 = [(2.2 1) 2 +
F1 = 62.3 KN

= 57192.7 mm 2

260
220
]
(200) (2.5) 400

= 1.078

6.85 tonf

dw2 = 208 + 2(2.6) + 2(25) = 263.2 mm

A2 = (400 2 (263.2) 2 )
p2 = [(2.2 1) 2 +

= 71219.72 mm 2

208
220
]
(200) (2.5) 400

= 1.0208

F2 = 72.7 KN
7.4 tonf
dw3 = 181 + 2(2.6) + 2(16) = 218.2 mm
A3 = (400 2 (218.2) 2 )

= 88225.17 mm 2

p3 = [(2.2 1) 2 +

181
220
]
(200) (2.5) 400

F3 = 87.44 KN

8.92 tonf

= 0.9911

51

Blank Holder Force-base on the fomrnig practical engineering

10
9

8.92

8
7.4
6.85

7
6

4
3
2
1
0
3rd Stage

1st Stage

2nd Stage

14

:3 ) (

)(Tonf

7,2

9,1

10

11

52

Tonf

Blank Holder Force - Exprimental

12

10

10
9.1

Tonf

7.2
6

0
1st Stage

2nd Stage

15

53

3rd Stage

 : )
(


.
.

- :

-

* .

- ) (


* .
.

-


.

54

 -
.

-

*
.

-


) : (16

)(Tonf

16
14
12
10
8
6
4
2
0
0

16

). ( P = F A

55

 :
.1
.
.
.2 .
1,2 1,5



... .


.
17
.


.

56

16
14

10
8
6
4

)(Tonf

12

2
0
3

17
18
.
.


) (uts )(yield
.


:
.1
.

.
.2
: n

57



.

.

.
.
) (

di

60
50

30
20
10
0
3

18

58

)(Tonf

40

60
50

30
20

)(Tonf

40

10
0
3

19

) : ( 19
.1

.
.2 .

59

1. V.Boljanovic , Sheet Metal Forming Processes and Die Design , 2004

2. H.Tschatsch , Praxiwissen Umformtechnik
( : )
3. Schuler , Metal Forming HandBook , 1998
4. I.Suchy , HandBook Of Die Design , 2006
5. K.Lange , HandBook Of MetalForming , 1985
6. C.Schnakovszky, B.Ganea , INFLUENCE Of Different Factors Concerning
The Wrinkling Of Cylindrical Deep-Drawn Parts , Fascicle of Management
and Technological Engineering, Volume VI (XVI), 2007
7. H.Gharib , A.S.Wifi , M.Younan , A.Nassef , Optimization Of the
BlankHolder Force In Cup Drawing , Journal of Achievements in Materials
and Manufacturing Engineering , Volume 18 , 2006
8. T.Yagami, K.Manabe, Y.Yamauchi , Effect Of Alternating Blank Holder
Motion Of Drawing and Wrinkle Elimination On Deep-Drawability ,
Journal of Materials Processing Technology ( 187188 ) , 2007
9. S. Yoshihara K. Manabea, H.Nishimura , Effect Of Blank Holder Force
Control In Deep-Drawing Process Of Magnesium Alloy Sheet , Journal of
Materials Processing Technology ( 579585 ) , 2005
10. S.H.Zhang , K.Zhang , Y.C.Xu , Z.T.Wang, Y.Xu , Z.G.Wang , DeepDrawing Of Magnesium Alloy Sheets At Warm Temperatures Journal of
Materials Processing Technology ( 147151 ) , 2007
11. D.M. Rodrigues , A. Loureiro , C. Leitao, R.M. Leal, B.M. Chaparro , P.

Vilaa , Influence of friction stir welding parameters on the microstructural

and mechanical properties of AA 6016-T4 thin welds , Materials and Design
30 (2009) 19131921

60

12. N. Abedrabbo , F. Pourboghrat , J. Carsley , Forming of AA5182-O and

AA5754-O atelevated temperatures using coupledthermo-mechanical finite
element models , International Journal of Plasticity 23 (2007) 841875
13. H. takuda , k. mori , I.masuda , Y.abe , M.matsuo Finite element simulation
of warm deep drawing of aluminium alloy sheet when accounting for heat
conduction ,
14. Lihui Lang , J. Danckert, K. Nielsen , Investigation into hydrodynamic deep
drawing assisted by radial pressure Part II. Numerical analysis of the
drawing mechanism and the process parameters , Journal of Materials
Processing Technology 166 (2005) 150161
15. Wenfeng Zhang, M.S. , DESIGN FOR UNCERTAINTIES OF SHEET
METAL FORMING PROCESS
16. N. Abedrabbo, A. Zampaloni, F. Pourboghrat , Wrinkling control in
aluminum sheet hydroforming , International Journal of Mechanical
Sciences 47 (2005) 333358
17. L. Lang, J. Danckert, K. Nielsen , Investigation into the effect of pre-bulging
during hydromechanical deep drawing with uniform pressure onto the
blank , International Journal of Machine Tools & Manufacture 44 (2004)
649657
18. S.H. Zhang , K. Zhang , Y.C. Xua , Z.T. Wang , Y. Xua , Z.G. Wang , Deepdrawing of magnesium alloy sheets at warm temperatures , Journal of
Materials Processing Technology 185 (2007) 147151
19. Internet : "http://www.thomasnet.com/"

61