Experimental and Theoretical Study of Square Deep Drawing


This work aim to study the effect of process parameters used in square deepdrawing operation such as ; die and punch profile radius, blank size, blank shape, onproduced cup wall thickness, strain distribution across the wall of the drawn part,punch force, earing shape and height of the drawn cup. 3-D model of square cup(41.4mm by 41.4mm), and 0.7 mm thickness from Low carbon steel (AISI 1008), hasbeen developed. Because of the symmetry in the specimen geometry, only one fourthportion of the model was needed to be analyzed using finite element method, acommercial available finite element program code (ANSYS 11), is used to performthe numerical simulation of the deep drawing operation, and the numerical results ofearing shape were compared with the experimental work. In this work, three types ofblank shape (circular, square, and octagonal), with different sizes, four types of punchprofile radii of 3, 5, 6, and 7mm and three types of die profile radii of 3, 5, 7mm havebeen chosen to form a square cup. The results show that, excessive earing will appearin the square cup when square blank was used, due to excessive material in the cornerand minimum material in the flat side, and when using octagonal blank which have anequivalent surface area to the square blank, the earing in the cup corner is reducedbecause of extraction of the excessive material from the corner of the blank. The bestresults were obtained from the circular blank, according to useful drawing height andearing.